The effects of spray-drying parameters on some chemical and physical characteristics of powdered phenol-formaldehyde resins

Liquid phenol-formaldehyde resin was synthesized and converted to the powdered form using a laboratory-scale spray-dryer. Drying parameters were varied to assess their effects on selected chemical and physical properties of the powdered resins produced. Resins with higher molecular weights resulted from higher inlet temperatures, lower feed rates, lower spray flows, and higher solution resin solids. Particle size distributions tended toward smaller values with lower inlet temperatures, greater feed rates, higher spray flows, and lower solution resin solids. Resins dried at lower temperatures retained a greater formaldehyde content than those dried at higher temperatures. A variety of particle shapes resulted from the drying process depending on the temperature experienced in drying and the solution resin solids.

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