Alumina slurries prepared in pilot plant scale have been characterized in terms of slurry rheology and stability and processed in a spray drier based on jet wheel impactor for atomization. Spheroidal alumina granules have been produced and their density, particle size and flowability behaviour are determined. Microstructure of the spheroidal granules has been observed under SEM and results are reported. The powders find application in plasma spray coatings, production of dense ceramic parts, components and tiles. (C) 2009 Elsevier B.V. All rights reserved.