Demonstrated Expertise

Pulse Combustion Systems has conducted a series of drying trials on algae produced for biofuel (https://en.wikipedia.org/wiki/Algae_fuel) and for food and nutriceutical use. The trials were conducted for one of the leading algal companies, and covered several different end uses. Plans are underway to begin large-scale toll drying, followed by site installation of a number of pulse dryers.

The pulse dryer produces a fine, free-flowing powder with minimal degradation, and easily handles high-viscosity concentrations of algae. The dryer handles algal slurries with intact cell walls as well as those that have been ruptured to release the oil.

Other methods of drying algal slurries are freeze drying, spray drying, and drum drying; pulse drying is superior to all of these methods. Freeze drying, for instance, makes a low-degradation product, but is an expensive batch process that often requires post-drying milling to make a fine powder. Spray drying is efficient, but can rupture intact cells in its high-pressure atomization process, and generally imparts unacceptable degradation due to time/temperature considerations. Drum drying exposes the algal slurry to long periods of elevated temperatures, and produces a flake that must be milled to obtain a fine powder. By comparison, the pulse dryer makes a fine powder like the spray dryer, and, due to very rapid drying, also delivers the low-degradation characteristic of freeze drying. In short, pulse drying delivers low-cost, high-throughput powders that have very high quality. Our customers therefore produce the best products at the least cost.

Pulse Combustion Systems is eager to demonstrate its technology for customers producing algal slurries that must be dried for stability, end use, extraction, or other processing. A summary of our development and commercialization processes can be found on our Getting Started page.

The best way to start evaluating pulse drying is to send an email to Gregory Stover, President, Pulse’s president, at gstover@pulsedry.com. We look forward to working with you.

For more information contact:
Gregory J. Stover, President
(563) 580-9996

PCS built and successfully demonstrated "prilling" operations by making minor changes to its standard pulse combustion spray dryer. The new system uses all of the existing "spray dryer" elements, and adds some special equipment for feed preparation and transportation.

Thus, customers can order from PCS a Pulse Combustion Spray Dryer, a Pulse Priller, or a "Combination Unit" that can switch from drying to prilling at the push of a button. The Combination Unit costs only about 25% more than either of the separate units.

PCS also demonstrated previously unseen small mean particle sizes for prills, allowing customers to develop new products around the tiny prills.

PCS also offers Contract Drying and Contract Prilling at its Payson, AZ plant.

For more information, contact:
Gregory Stover at gstover@pulsedry.com or (563) 580-9996.

Pulse Combustion Systems has extensive experience and success in drying lithium slurries for today’s high-tech batteries.  In particular, PCS has produced over 120 metric tons of lithium dihydrogen phosphate powder for one manufacturer, and has sold two dryers for lithium battery powder production to Altair Nanotechnologies in Reno, Nevada.

In addition to practical experience, PCS has discovered some unique characteristics only available through pulse drying, and has applied for a patent covering these advantages.

The success in lithium slurries is an outgrowth of the generally excellent results from the pulse-drying of minerals and metals.  The PCS dryer is highly efficient, delivers powders with uniform surface characteristics and tight particle size distributions, and is impervious to abrasion and chemical attack.  This resistance to chemical attack and abrasion is due to the pulse dryer’s unique low-pressure “gas-dynamic” atomization method that completely avoids high-pressure pumps, spray nozzles, and rotary disks.  Maintenance costs, therefore, are extremely low.  An overview of how the dryer works can be seen on our Pulse Technology page.

Pulse Combustion Systems is eager to demonstrate its technology for customers who are manufacturing battery materials.  A summary of our demonstration, development and commercialization processes can be found on our Getting Started page.

The best way to start evaluating pulse drying is to send an email to Gregory Stover, Pulse’s president, at gstover@pulsedry.com.  We look forward to working with you.

For more information contact:
Gregory J. Stover, President
(563) 580-9996

Pulse Combustion Systems has conducted a series of drying trials on cyclodextrins (https://en.wikipedia.org/wiki/Cyclodextrin) and cyclodextrin complexes, and has proven that pulse technology produces a dry powder that is far better than what can be produced in a conventional spray dryer, and creates a powder quality that rivals that produced by freeze drying.  (Freeze drying is a capital-intensive “batch” process which is much more expensive than pulse drying.  Pulse drying, like spray drying, is a continuous process requiring a minimum of labor.)

The drying trials were so successful that we have prepared a patent application with respect to the pulse drying of cyclodextrins and cyclodextrin complexes.

As for all other products, Pulse Combustion Systems is prepared to conduct product development activities for customers interested in cyclodextrins and cyclodextrin complexes.  Our first such development round was for NanoSonic Products, Inc., and our second will commence within 60 days.  A summary of our development and commercialization processes can be found on our Getting Started page.

The best way to get started on this process is to send an email to Gregory Stover, Pulse’s president, at gstover@pulsedry.com.  We look forward to working with you.

For more information contact:
Gregory J. Stover, President
(563) 580-9996

In response to a customer request, Pulse Combustion Systems (PCS) developed and prototyped an "indirectly-heated" version of its Pulse Combustion Dryer. Instead of burning fuel in a combustion chamber, this new dryer employs either an electric heating element or a heat exchanger to heat the drying gas. Thus, the drying gas can be pure air (or CO2, or N2), with no combustion byproducts, and no potential for flame contact with the products to be dried.

This new dryer model allows PCS to:

  • Dry products with extreme purity requirements,
  • Dry any product that is sensitive to combustion byproducts,
  • Meet regulatory requirements that may prohibit "direct contact" heating of the drying air, and
  • Handle any feed material containing flammable solvents.

PCS prototyped the new dryer design by converting its existing Pilot Dryer to use air heated by an electric coil. (A conventional heat exchanger could also be used.) The prototype worked perfectly, and the new dryer retained all the other great attributes of pulse drying - gas-dynamic atomization and rapid drying, minimal product degradation, consistent particle size, and high efficiency, all controlled by PCS's advanced dryer control system.

Based on the excellent Pilot Dryer results, PCS was fortunate to receive an order from Orbite Aluminae, Inc. for the first Indirect Pulse Dryer. Orbite will use the new Pulse Dryer in the production of High Purity (.9999) Alumina. The Dryer is almost complete, with commissioning expected in January 2013.

The company's Indirect Pulse Dryer Prototype is available for Pilot Trials of customer products.

For more information contact:
Gregory J. Stover, President
(563) 580-9996
gstover@pulsedry.com

Pulse Combustion Systems (PCS) has been developing expertise in drying certain components of Hydraulic Fracturing Fluid that need to be delivered in a dry form to the oil and natural gas fields. These additives are designed to enhance the output and longevity of each well by performing specific functions in the well.

PCS was contacted by companies working in this fast-growing market. They were looking for quick development of the drying parameters, toll-drying to enable instant marketplace entry, and fast delivery of modular dryers to remote sites. PCS provides all three.

The PCS pulse combustion dryer is perfect for this application, because it is efficient, highly resistant to abrasion and corrosion, and able to handle a wide variety of liquid inputs, including those with solid particles - called 'proppants.'

The PCS Dryer is also perfect for remote locations, because it runs on a variety of fuels, is extremely reliable, and requires almost no maintenance.

PCS welcomes customer inquiries, and is ready to conduct Pilot Trials on customer products on short notice.

For more information contact:
Gregory J. Stover, President
(563) 580-9996
gstover@pulsedry.com

In response to requests from companies working in the industry, Pulse Combustion Systems (PCS) has developed and implemented a new high-temperature drying system.

Certain processes require elevated temperatures in the drying chamber while spray drying, and these are very hard to obtain in conventional spray drying.

PCS's pulse dryers can produce combustion air at up to 2,000 degrees F, at very high volume, which can heat up a drying chamber quickly, and allow "normal" spray drying functions at dryer outlet temperatures as high as 600F.

PCS welcomes customer inquiries, and is ready to conduct Pilot Trials on customer products on short notice.

For more information contact:
Gregory J. Stover, President
(563) 580-9996
gstover@pulsedry.com

Pulse Combustion Systems (PCS) has recently developed, fabricated, and implemented a new Fluid Bed section for use in its Pilot Dryer.

The Fluid Bed is mounted at the bottom center of the spray dry chamber, and powder produced in the upper section of the drying chamber falls into the bed by gravity as the drying air is extracted from the top of the dryer.

The Fluid Bed is fitted with an under-bed air inlet system. The pressure of the air is controllable (thus influencing bed height and agitation), and the temperature of the air can be changed to either heat or cool the powder.

The Fluid Bed gives PCS the ability to impart more residence time, and also to introduce other elements such as flow agents or agglomeration aids.

PCS welcomes customer inquiries, and is looking for additional customer trial opportunities.

For more information contact:
Gregory J. Stover, President
(563) 580-9996
gstover@pulsedry.com

Pulse Combustion Systems (PCS) has purchased a homogenizer for use in preparing emulsions and other products containing fats (such as whole milk) for pulse drying. The homogenizer's output will match the input of the PCS Pilot Dryer.

The PCS Pulse Dryer has always done a great job on emulsions and other products containing lipids, but will now be able to turn out even better powders. Pulse drying tends to preserve lipids to a far greater extent than conventional spray drying.

PCS welcomes customer inquiries about lipid-containing products, and looks forward to conducting Pilot Trials for customers.

For more information contact:
Gregory J. Stover, President
(563) 580-9996
gstover@pulsedry.com

Pulse Combustion Systems has implemented a comprehensive food safety and quality system for its operations in Payson, AZ.

We have created and implemented a Quality Manual, and a standalone Standard Operating Procedure (SOP) for each toll-drying or toll-manufacturing customer.

We have accomplished the following:

  • FDA Food Facility Domestic Registration. Registration number 10467722220.
  • Kosher Certification via Kosher Supervision of America, Los Angeles
  • A successful quality audit by a major medical device packaging manufacturer, including satisfactory IQ, OQ, and PQ trials.
  • A successful quality audit by a major supplier of pharmaceutical excipients.
  • A successful quality audit by a Fortune 500 industrial manufacturer.

We plan the following activities for 2014:

  • A Third-Party GMP audit in First Quarter 2014
  • A Global Food Safety Initiative (GFSI) audit by December, 2014
  • Organic and Halal Certifications

For more information contact:
Gregory J. Stover, President
(563) 580-9996
gstover@pulsedry.com

SUBSCRIBE NOW!
Receive weekly recommendations right in your inbox.
FILL OUT FORM FOR DOWNLOAD!
We hate spam and never share your details.
FILL OUT FORM FOR DOWNLOAD!
We hate spam and never share your details.
FILL OUT FORM FOR DOWNLOAD!
We hate spam and never share your details.
FILL OUT FORM FOR DOWNLOAD!
We hate spam and never share your details.
FILL OUT FORM FOR DOWNLOAD!
We hate spam and never share your details.
FILL OUT FORM FOR DOWNLOAD!
We hate spam and never share your details.
FILL OUT FORM FOR DOWNLOAD!
We hate spam and never share your details.