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    Spray Dryer Design

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    Jan Benner
    1. Spray dryers transform liquid foods into powder by pumping the liquid through a nozzle where it is atomized into droplets and dried by hot air as they fall through the chamber. 2. Rotary atomizers are widely used in the food industry as they can handle a range of viscosities and produce a homogeneous spray. They project droplets horizontally at high speeds. 3. Pneumatic dryers continuously dry food particles or powder in a vertical duct while being conveyed by heated air. One or more cyclones are used to separate the dried material from exhaust air. They allow use of relatively high air temperatures without overheating products.

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    Spray Dryer Design

    Uploaded by

    Jan Benner
    5K views24 pages
    1. Spray dryers transform liquid foods into powder by pumping the liquid through a nozzle where it is atomized into droplets and dried by hot air as they fall through the chamber. 2. Rotary atomizers are widely used in the food industry as they can handle a range of viscosities and produce a homogeneous spray. They project droplets horizontally at high speeds. 3. Pneumatic dryers continuously dry food particles or powder in a vertical duct while being conveyed by heated air. One or more cyclones are used to separate the dried material from exhaust air. They allow use of relatively high air temperatures without overheating products.

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    Spray Dryer Design Ppt

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    Spray Dryer Design Ppt

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    1. Spray dryers transform liquid foods into powder by pumping the liquid through a nozzle where it is atomized into droplets and dried by hot air as they fall through the chamber. 2. Rotary atomizers are widely used in the food industry as they can handle a range of viscosities and produce a homogeneous spray. They project droplets horizontally at high speeds. 3. Pneumatic dryers continuously dry food particles or powder in a vertical duct while being conveyed by heated air. One or more cyclones are used to separate the dried material from exhaust air. They allow use of relatively high air temperatures without overheating products.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    5K views24 pages

    Spray Dryer Design

    Uploaded by

    Jan Benner
    1. Spray dryers transform liquid foods into powder by pumping the liquid through a nozzle where it is atomized into droplets and dried by hot air as they fall through the chamber. 2. Rotary atomizers are widely used in the food industry as they can handle a range of viscosities and produce a homogeneous spray. They project droplets horizontally at high speeds. 3. Pneumatic dryers continuously dry food particles or powder in a vertical duct while being conveyed by heated air. One or more cyclones are used to separate the dried material from exhaust air. They allow use of relatively high air temperatures without overheating products.

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    The key takeaways are that spray dryers transform liquids into powders by atomizing the liquid into droplets and drying them using hot air. The liquid is pumped through a nozzle and atomized into droplets, which are then dried as they fall through a chamber of hot air.

    The main components of a spray dryer are the feed system, atomizer, drying chamber, air supply system, and product collection system. The liquid is pumped through an atomizer nozzle where it is atomized into droplets and dried by hot air as the droplets fall through the chamber.

    The two main types of atomizers used are pressure atomizers and rotary atomizers. Pressure atomizers use pressure to force liquid through a small nozzle, producing droplets of narrow size. Rotary atomizers use centrifugal force from a spinning wheel to produce droplets, allowing for a wider range of viscosities. Rotary atomizers are more widely used in food applications.

    DRYER DESIGN

    AGEN/CHEN-474 UNIT OPERATIONS IN FOOD PROCESSING

    SPRAY DRYER-SD
    in a SD, foods are transformed from pumpable liquid into powder the liquid is pumped through a nozzle, where it is atomized the droplets are dried by hot air as they fall to the bottom of the chamber

    SPRAY DRYER
    feed air heater atomizer air out

    air broom

    air out

    product out

    SPRAY DRYING
    advantageous for heat sensitive products because the particles are never subjected to a temperature higher than the wet-bulb temperature of the drying air particles residence time is short (3 - 30 s)

    SPRAY DRYING OPERATION


    is divided into 3 distinct processes - atomization -drying through the contact between the droplets and heated air -collection of the product by separating it from the drying air

    ATOMIZATION
    the type of atomizer is important because it determines: the energy required to form the spray, size and distribution of the droplets, available heat transfer area, drying rate, droplet speed and trajectory, and final product size types: hydraulic nozzles and rotary nozzles

    Pressure Atomizer
    used to create droplets by forcing the liquid trough a small orifice (0.4-4mm) maximum flow rate of 1L/h pressure range from 300 to 4000 psig seldom used when feed is highly concentrated (clogging) droplets have narrow range of diameter and the dried product consists of hollow spheres operating costs lower than rotary nozzles

    Rotary Atomizer
    liquid is fed to the center of the spinning wheel under centrifugal force droplets are guided and shaped by vanes in the wheel droplets are projected horizontally away at 100 to 200 m/s with angular velocities of 10,000 to 30,000 rpm used for slurries and paste (no clogging) produces homogeneous spray mean particle diameter can be controlled by varying rotational speed widely used in the food industry because it can handle a wide range of liquid viscosities and physical property

    1- DROPLET-SIZE CALCULATION
    vary with nozzle type and feed material estimation can be with following equations, but actual test is required for rotating wheel atomizers:

    l L Da =12.2 10 r Nr2 2 l
    4

    0.6

    0.2

    0.1

    Da=average particle size (m) = surface tension of liquid (lb/min 2 ) l = liquid density (lb/ft 3 ) r = disk radius (ft) = spray mass velocity per foot of disk periphery (lb/ft.min) N = disk speed (rpm) L = disk periphery (ft)

    1- DROPLET-SIZE CALCULATION
    for pressure atomizers it requires only the pressure drop across the nozzle

    500 Da = 1/ 3 P
    Da=average particle size (m) P = pressure drop across the nozzle (psi)

    2- DRYER CHAMBER DESIGN


    depends on the type of atomizer, the airflow pattern, the production rate, when drying heat sensitive product, the temperature profile of the air in the chamber the shape of the drying chamber is a fnc of the droplets trajectory angle as they leave the atomizer the chamber must be sized so that the largest droplets is dry before it contacts a wall

    Range of Droplets and Particle Sizes obtained in Spray Dryers (m)


    rotating wheels pressure nozzles pneumatic nozzles milk coffee 1-600 10-800 6-300 30-250 80-400

    3 - AUXILIARY EQUIPMENT
    varies with spray dryer design most common are air heaters and fans most common heater in FI is steam heater (saturated steam at 150 to 200C is used to heat the air up to 10C bellow the steam temperature) centrifugal fans because they produce high air flow rates

    4- AIRFLOW PATTERNS
    3 airflow patterns: concurrent, countercurrent, mixed flow
    concurrent F S G countercurrent F G P G G S G P

    4- AIRFLOW PATTERNS
    mixed (combined) most used for heat-sensitive product is the concurrent because G product temperature is less than inlet air temperature if high-density products G F countercurrent if size of dryer is limited - mixed S G flow P

    5- CALCULATION OF HEAT INPUT

    q = ha (T ) As
    ha = dry air film coefficient (J/m^2K) = temperature of solid (K) T = temperature of thedry air (K) As = surface area of the solid (m^2)

    6- CALCULATION OF THERMAL EFFICIENCY


    =
    & G(T Twb )CPA + m( Twb )CPF & M CH h fg

    MCH=chamber evaporation capacity (kg water/s) hfg = latent heat of vaporization (J/kg) G = airflow rate (kg/s) m = feed flow rate (kg/s) . CPA = heat capacity of air (J/kgK) CPF = heat capacity of the feed (J/kgK) T = air temperature (C) = feed temperature (C)

    7- PRODUCT COLLECTION
    if the product separates from the air at the bottom of the conical chamber, it is removed through a auger it is common to product to remain entrained in the air stream, so cyclones are used to recover the product

    8- USE OF SPRAY DRYERS


    flavor encapsulation: food flavorings are combined with gums and carbohydrates before drying to prevent loss of volatile

    9- FOOD QUALITY FACTORS


    volatile retention is a problem with SD - loss of volatile is minimized by increasing the particle diameter (as), decreasing feed temperature (lower the liquid-phase diffusion coefficient), and decreasing the air temperature (minimizing particle expansion) thermal degradation is a problem for droplets that remain in the hot portion of the dryer for too long

    10- Drying Time


    t=

    h d

    2 L fg o

    8ka(T Twb)

    d h (Mcr Me)
    2 p c fg

    k 12 aTave

    do = initial diameter of droplet (m) dc = droplet diameter at critical moisture Mcr (m) ka = thermal conductivity of air (W/mK)
    DTave = average temp. difference between air and product (C)

    FLASH OR PNEUMATIC DRYERS


    in a PD the food, powder or particles, is continuously dried in a vertical duct while being conveyed by the heated air one or more cyclones are used to separate the dried material from the exhaust air small particle sizes (less than 2 mm) and concurrent operation allow the use of relatively air temperatures without overheating the product

    SCHEMATIC OF A PNEUMATIC DRYER


    wet product fan feeder cyclone exhaust air

    burner fan

    dry product

    VELOCITY CALCULATIONS
    two limit velocities are important in fluidization and pneumatic transport of solids, the fluidization velocity, vf, and entrainment velocity, ve

    gD p ( w ) = 180 (1 )
    2

    ve =

    gD

    ( s

    18

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