Atomizing vs Granulation

Hi All

As a process engineer (Metallurgical) I have been asked if it is possible to granulate molten metal to get particle sizes smaller than 500 micron (0.5mm). My answer was that it sure is possible if you have high enough water pressure and flow rate in the granulator.

However, in order to test this I would like to build a small granulation unit and an atomizing unit. I went on the internet and got quotes for an atomizer, but at US$1.5 million, it is a bit steep for my budget. Does anyone have experience in the design of said equipment?

Here are my thoughts:

Granulator: To granulate Copper, 2T per hour, I will use 100 liter water per hour at 10 Bar pressure. The "striking pad" is in the middle of the stream (water sprayed through a slit in a box to create a ribbon 3mm thick, 200mm wide), and running down a chute 3.6m long.

Atomiser: To atomise 2T/h Copper, I will use 100 liter water per hour at 50 Bar pressure. The "striking pad" is in the middle of a circle of jets. The jets are produced with nozzles (20 of them), directed 30 degrees downward and inward, all spraying exactly in the same spot. The atomised metal will then fall down a chamber and be caught in a removable cone. (I have not made any drawings of this yet.

Any comments will be appreciated.

TC