SlideShare a Scribd company logo
1 of 15
Download to read offline
GBH Enterprises, Ltd.

Process Engineering Guide:
GBHE-PEG-DRY-006

Spray Drying

Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Process Engineering Guide:

Spray Drying

CONTENTS

SECTION

0

INTRODUCTION/PURPOSE

2

1

SCOPE

2

2

FIELD OF APPLICATION

2

3

DEFINITIONS

2

4

BACKGROUND TO TEST FACILITIES

3

5

DESIGN PROCEDURE

4

6

TEMPERATURE SENSITIVE PRODUCTS

4

7

FEEDSTOCK PREPARATION

5

8

FEEDSTOCK ATOMIZATION

5

9

PRODUCT COLLECTION

5

10

SAFETY ASPECTS

5

11

MICROSTRUCTURE OF DRIED PARTICLES

6

12

HYBRID DRYERS

6

13

BIBLIOGRAPHY

6

APPENDIX
A CONTENTS LIST FOR SPS DRYING MANUAL
VOLUME V PART 1

7

DOCUMENTS REFERRED TO IN THIS PROCESS
ENGINEERING GUIDE

10

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
0

INTRODUCTION/PURPOSE

Spray drying is a relatively expensive method of drying, but is particularly
recommended when the product is temperature-sensitive (due to the very short
time that the product experiences elevated temperatures) or if the typical physical
form of a spray dried product (spheroids with a median diameter of up to 250
micron) is desirable. Another advantage of spray drying is that it produces a very
homogeneous product from multi-component feedstocks. A prerequisite is that
the feed can be pumped and atomized.
Spray drying, with co-current air/feedstock flow, is used extensively within some
companies for drying specialty products (dyes, pigments, intermediates,
surfactants, ceramics, biodegradable polymer). Target moisture contents down to
about 0.1% can be achieved if the feedstock is a dispersion with little or no
material in solution. However as the proportion of dissolved material
increases, and particularly when that material can form a skin on drying, then
realistic target moisture contents increase. With typical dyestuff formulations it is
difficult to achieve moisture contents less than 2%, and a typical target moisture
would be 4 to 5%.
If very low moisture contents are required, then a counter-current design of spray
dryer could be considered where almost dry particles experience the highest air
temperatures. However this mode of operation is not suitable for temperaturesensitive products. Alternatively, a combination of co-current spray drying and
e.g. fluid bed drying should be considered.

1 SCOPE
This Guide deals with spray drying including the need for trials and the
availability of test facilities.

2 FIELD OF APPLICATION
This Guide applies to process engineers in GBHE Enterprises worldwide.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
3

DEFINITIONS

For the purposes of this Guide, the following definition applies:
SPS

The Separation Processes Service (SPS) is a research and
consultancy organization, based at Harwell and Warren Spring
Laboratory. It is active in the main operations related to separation,
including comprehensive coverage of drying.

With the exception of terms used as proper nouns or titles, those terms with initial
capital letters which appear in this document and are not defined above are
defined in the Glossary of Engineering Terms.

4

BACKGROUND TO TEST FACILITIES

When spray drying is identified as a possible method of drying a material, trials
are carried out in-house on pilot plant facilities and also on manufacturers' test
facilities to confirm that spray drying is a suitable technique for the feedstock.
The smallest (laboratory scale and 0.8 metre diameter Niro Mobile Minor) spray
dryers will give some idea of whether a feedstock will spray dry, but a negative
result should not necessarily preclude the use of a full scale spray dryer.
The Niro Production Minor dryer (1.2 metre diameter) is the smallest scale
recommended to give indications of potential problems such as adherence of
product to ducting walls etc. However even at this scale the particle size is
unlikely to be as big as that required from a full scale dryer and the product may
not be representative of product from a full scale dryer, e.g. in terms of
dispensability. Large scale trials are necessary to check the quality of the spray
dried product and to give some guidance of the likely size of installation
necessary to achieve the desired production rate.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
European Manufacturer, trial facilities:
(a) Lab-scale dryers
(b) Niro Mobile Minor
(c) Niro Production Minor
(d) Larger scale dryers

There are a limited number of reputable suppliers of spray drying equipment. In
Western Europe, the main suppliers are:
(1) Niro Atomizer A/S
Denmark
(2) APV Pasilac Anhydro A/
Denmark
(3) Drytec Ltd
Tonbridge, Kent , U.K.
(4) Barr and Murphy Overseas Ltd
Maidenhead, Berks, U.K.

5

DESIGN PROCEDURE

A design procedure for co-current spray dryers is given in Ref. [1] (the contents
of which are listed in Appendix A), produced by SPS. Copies of Ref. [1] and
may be ordered from SPS.
A design procedure is included in Ref. [2].
SPS also provide several software packages (SPRY1, SPRY2A, SPRY2B,
SPRY2C) to perform moisture and energy balances and preliminary sizing
calculations for co-current spray dryers with a variety of different heating
methods (direct and indirect firing, once-through versus total recycle of the drying
gas). These are described in Ref. [3].

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
6

TEMPERATURE SENSITIVE PRODUCTS

While spray drying is recommended for the drying of temperature-sensitive
products, there is evidence that some designs of spray dryer ("tower" dryers, i.e.
tall, narrow types designed for nozzle atomization) are better than others (squat
form types designed for rotary atomizers). The reason is believed to be that in
the squat form types, the large gas recirculation zones entrain particles
(particularly the smaller ones) which therefore have prolonged residence times
and become over dried. Such recirculation zones are likely to be much smaller in
tower dryers.

7

FEEDSTOCK PREPARATION

Feedstock preparation is discussed in, “Paste Preparation Systems for Dryers”.
Some additional comments are given below:
(a) Spray dryers have to have a feedstock which is fluid enough to pump to the
atomizer. With dispersion feedstocks, particularly when the particles have a high
aspect ratio, the limiting total solids content for a pumpable feedstock may be
less than 20%. The addition of a small amount of a suitable surfactant, where this
is permitted in the dry product, can greatly increase the pumpable concentration.
(b) If the concentration of the feedstock is such that a small increase in total
solids (e.g. by 1 or 2%) would cause a large increase in viscosity, this could
interfere with the atomization process to give strands rather than droplets, and
the feedstock concentration should be reduced.
(c) With feedstocks containing dispersed particles, there is an upper limit to the
size of these particles beyond which blockage problems arise. This upper size
limit is smaller for nozzle atomizers, which have narrow channels which the feed
has to negotiate, than for rotary atomizers.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
8

FEEDSTOCK ATOMISATION

A key aspect of spray drying is atomization of the feedstock. Atomization is
covered in Ref. [5] “Atomization in Spray Dryers (Operational Manual)”,
GBHE recommends mainly pressure nozzles and rotary atomizers, and to a
limited extent the use of fluid nozzles.
Work is underway to develop novel atomizers for spray drying, to give narrower
drop size distributions and hence less dusty products. The narrower drop size
distributions are likely to reduce the extent of entrainment in recirculation zones
which causes prolonged residence times in the dryer.

9

PRODUCT COLLECTION

Product leaves the dryer both from the rotary valve in the base of the drying
chamber and from the drying air exhaust stream. The particle size distribution in
the rotary valve will be coarser than in the exhaust stream. Use is often made of
this classification effect to reduce the dustiness of the product, by collecting only
the product from the chamber for further use or sales, while the fines in the air
stream are separated off and recycled, usually by re-dispersing in the feedstock.
Separation of the fines from the air stream is usually carried out by cyclone,
though bag filters are used for some products where there is a high proportion of
very fine particles.

10

SAFETY ASPECTS

By their nature, spray drying facilities pose a risk of dust cloud explosions. The
risk of explosions or fires is minimized by:
(a) The use of operating conditions, particularly maximum air inlet temperatures,
defined from appropriate flammability and explosion severity tests. In extreme
cases, it may be necessary to operate with inert drying gas in a closed cycle.
(b) Minimizing build-up of dried product in the dryer and associated ductwork.
Use is often made of automatic hammers on the dryer chamber to disturb
product adhering to the chamber wall.
(c) The use of explosion suppression equipment where appropriate.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Explosion suppression equipment is not appropriate for large spray dryer
chambers and so these are normally fitted with explosion relief panels to vent
any explosion, thereby avoiding major damage.
The subject of fire and explosion hazards in dryers is covered by GBHE-PEGDRY-005 and Ref. [6].
Where the product is toxic, the dusty nature of spray dried products poses
particular problems both in terms of the obvious need to protect operators from
exposure to the product and also the less obvious fact that, in the event of an
explosion, the opening of relief panels allowing the toxic product to be blown into
the environment might not be acceptable.

11

MICROSTRUCTURE OF DRIED PARTICLES

The quality of spray dried products can be affected by the microstructure of the
dried particles. This is controlled mainly by the nature of the feedstock, and to a
lesser extent by the drying conditions. The relationship between particle
microstructure and feedstock is discussed in “Spray Drying: The Qualitative
Effect of Factors Governing the Packing Density and Dustiness of Spray Dried
Products”, W M L Wood (1987).
An awareness of this relationship can influence the range of feedstock
parameters and drying conditions to be used, which in turn can influence the final
design and size.

12

HYBRID DRYERS

In addition to conventional spray dryers, hybrid dryer systems are offered by
some manufacturers. Such systems combine spray drying with fluid bed drying.
Several manufacturers design systems with a separate fluid bed fed from the
spray dryer. Niro offer a single unit, their FSD dryer, in which a fluid bed dryer is
incorporated in the base of a co-current spray dryer. Such units offer improved
thermal efficiency and, particularly in the case of the FSD, the opportunity to
produce a granulated product with reduced dust content.
The design of combined systems with a fluid bed dryer following a spray dryer
can be achieved using the design guides for the individual dryer types, and
optimizing the thermal efficiency by choosing appropriate moisture contents for
the product exiting the spray dryer and entering the fluid bed.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
13

BIBLIOGRAPHY

[1] Drying Manual, Volume V (Spray Drying) Part 1, SPS, Harwell
[2] Industrial Drying Equipment - Selection and Application, C M van't Land,
Marcel Dekker (1991)
[3] Drying Manual, Volume V (Spray Drying) Parts 3 and 4, SPS, Harwell.
[4] The Spray Drying Handbook, 5th edition, K Masters, Longman (1992).
[5] Drying Manual, Volume V (Spray Drying) Part 2, SPS, Harwell
[6] The Prevention of Fires and Explosions in Drying, 2nd edition, J Abbott,
IChemE, (1991).

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
APPENDIX A CONTENTS LIST FOR SPS DRYING MANUAL
VOLUME V PART 1
(A Practical Guide to Selection and Design of Spray dryers)
Page No
1

INTRODUCTION

1.7

1.1
1.2
1.3

Background and purpose
Scope and limitations
Report format

1.7
1.7
1.7

2

DESIGN GUIDE

1.9

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9

Preliminary examination of data
Rough sizing on basis of air throughput
Flowsheet considerations
Atomization method and chamber diameter
Chamber selection
Other considerations and design methods available
Programmable calculator program (Texas T159)
Psychrometric chart calculations
Example calculation illustrating psychrometric chart
design method
2.9.1 Specification of requirements
2.9.2 Solution procedure

1.9
1.9
1.9
1.9
1.11
1.11
1.11
1.14

3

FLOWSHEET CONSIDERATIONS

1.24

3.1
3.2

Is the liquid to be removed water or some other material?
Is there any volatile material present in the feed other
than water or solvent that is likely to cause problems?
Is the product or solvent toxic, carcinogenic, irritating or
the like?
Is the product a dust explosion risk?
Does the product suffer from exposure to oxygen at
drying temperatures?
Is the product sensitive to products of combustion?
Is the product permanently damaged by heat within
the exposure times applying in spray dryers?
Can the dried product be sticky, or suffer temporary
thermal damage?

1.24

3.3
3.4
3.5
3.6
3.7
3.8

1.17
1.17
1.17

1.24
1.24
1.24
1.25
1.25
1.25
1.26

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
3.9

3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19

Is there a maximum temperature for final discharged
product?
Could the final product be discharged with advantage at
a single point other than at the dryer itself?
Is the spray dryer the first stage of a multi-stage drying
system?
Is product particle size classification necessary or desirable?
Is heat available from an external source?
What are the limits on emissions to atmosphere?
Is heat recovery from dryer exhaust desirable?
Can the product foam in water/solvent?
Can the feed liquid foam? 1.28
Are there acoustic limits to be met?
Must special attention be paid to hygiene and cleanability?

4

CAPACITY CONSIDERATIONS

1.29

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9

Agreement on required capacity
Evaporative load variations
Effects of transient and abnormal conditions
Shutdown and cleaning outages
Periodic maintenance requirements
Maintenance of efficient operating conditions
Effect of product properties
Plants for multiple products
Feedstock concentration

1.29
1.29
1.29
1.29
1.29
1.30
1.30
1.30
1.30

5

ATOMIZATION CHARACTERISTICS AND SELECTION

1.32

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12

Methods available
Centrifugal atomizers
Pressure nozzles
Pneumatic (two-fluid) nozzles
Maximum particle size in feedstock
Spray-air mixing
Cost comparison
Product granulometry
Erosion problems
Use of multiple atomizers
Design choices
Size distribution of spray droplets

1.32
1.33
1.33
1.33
1.33
1.33
1.33
1.34
1.34
1.34
1.34
1.34

3.10
3.11

1.26
1.26
1.27
1.27
1.27
1.27
1.28
1.28
1.28
1.28

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
5.13
5.14
5.15

Atomizer selection
Re-examination of product specification
Atomizer choice (summary)

1.36
1.36
1.36

6

DRYING CHAMBERS

1.37

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14

Introduction
Box-type dryers
Cylindrical dryers
Choices in chamber design parameters
Chamber designs commonly used
Applications of various chamber designs
Selection of standard size and shape
Definition of chamber volume facto
Effect of atomization and airflow on chamber design
Prevention and removal of deposits from chamber walls
Floor sweepers for flat-bottomed chambers
Designing for explosion risks in the dryer
Largest median particle size for given chamber diameter
Consideration of gas residence time in chamber sizing

1.37
1.37
1.37
1.37
1.40
1.40
1.41
1.41
1.41
1.43
1.43
1.43
1.44
1.44

7

SELECTION OF DESIGN PARAMETERS

1.45

7.1
Fixed design data
7.2
Parameters which may be varied
7.3
Detailed consideration of design variables
7.3.1 Flowsheet
7.3.2 Oxygen level
7.3.3 Condenser temperature
7.3.4 Inert gas
7.3.5 Partial recycle of exhaust gas without condensation
7.3.6 Heating means
7.3.7 Wet recycle of fines
7.3.8 Scrubber liquor
7.3.9 Cold air additions
7.3.10 Floor sweeper air
7.3.11 Atomization
7.3.12 Dryer air inlet temperature
7.3.13 Dryer air outlet temperature
7.3.14 Residence time
7.4
Design data questionnaire

1.45
1.45
1.45
1.46
1.46
1.46
1.46
1.46
1.47
1.47
1.47
1.47
1.48
1.48
1.48
1.49
1.51
1.55

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
NOMENCLATURE

1.58

REFERENCES

1.59

APPENDICES
App.
A.1
A.1.1
A.1.2
A.1.3
A.1.4
A.1.5
A.2
A.2.1
A.2.2

Derivation of equations in Chapter 2
Equation (2.1)
Equation (2.3)
Equation (2.7
Equation (2.4)
Equation (2.2)
Calculator program for Texas TI59
Program equations
Program listing

1.60
1.60
1.60
1.61
1.61
1.61
1.63
1.63
1.64

TABLES
Table
2.1
2.2
5.1
6.1
6.2
7.1

Values of fuel moisture rate, fmr
Psychrometric chart data state
Major characteristics of atomizers
Volume factors for dryer chambers
Recommended chamber shapes
Drying conditions used on some products

1.13
1.15
1.32
1.41
1.42
1.53

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
ILLUSTRATIONS
Fig
2.1
2.2
2.3
2.4
2.5
5.1
5.2
6.1
6.2
7.1
7.2

Computer program results
Psychrometric chart for once-through, direct-fired dryer example
Psychrometric chart showing effect of cold air addition
Psychrometric chart for direct-fired system with partial
exhaust recycle
Psychrometric chart showing effect of an exhaust gas scrubber
Typical product particle size distribution for three atomizer types
Extreme and typical product particle size ranges for three different
atomizer types
Chambers for centrifugal atomizers
Chambers for nozzle atomizers
Relationship between product moisture content and
air outlet temperature
Typical dryer design data questionnaire

1.14
1.20
1.21
1.22
1.23
1.35
1.35
1.38
1.39
1.50
1.56

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

More Related Content

What's hot

Oleochm- phy refining
Oleochm- phy refiningOleochm- phy refining
Oleochm- phy refiningPeggy
 
Efficient use of steam in heat exchanger
Efficient use of steam in heat exchangerEfficient use of steam in heat exchanger
Efficient use of steam in heat exchangeriqbal_abbas93
 
Processing of Margarine
Processing of Margarine Processing of Margarine
Processing of Margarine Maira Jabeen
 
An overview of encapsulation technologies for food
An overview of encapsulation technologies for foodAn overview of encapsulation technologies for food
An overview of encapsulation technologies for foodnooshin noshirvani
 
Troubleshooting in Distillation Columns
Troubleshooting in Distillation ColumnsTroubleshooting in Distillation Columns
Troubleshooting in Distillation ColumnsGerard B. Hawkins
 
Evaporator performance
Evaporator performanceEvaporator performance
Evaporator performanceMamta Sahurkar
 
Design and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation ColumnsDesign and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
 
invert sugar syrup.pptx
invert sugar syrup.pptxinvert sugar syrup.pptx
invert sugar syrup.pptxParulThapar2
 
Distillation Column
Distillation ColumnDistillation Column
Distillation ColumnKhalid Nawaz
 
Advance in mass transfer in food application
Advance in mass transfer in food applicationAdvance in mass transfer in food application
Advance in mass transfer in food applicationDayanand Raj
 
Confectioneries - Food Technology
Confectioneries - Food TechnologyConfectioneries - Food Technology
Confectioneries - Food Technologyindumathi balaji
 
Agitation & mixing presentation, group d
Agitation & mixing presentation, group dAgitation & mixing presentation, group d
Agitation & mixing presentation, group dRezwana Nishat
 

What's hot (20)

Oleochm- phy refining
Oleochm- phy refiningOleochm- phy refining
Oleochm- phy refining
 
Spray drying pdf In food industry.
Spray drying pdf In food industry. Spray drying pdf In food industry.
Spray drying pdf In food industry.
 
Efficient use of steam in heat exchanger
Efficient use of steam in heat exchangerEfficient use of steam in heat exchanger
Efficient use of steam in heat exchanger
 
Processing of Margarine
Processing of Margarine Processing of Margarine
Processing of Margarine
 
Emulsifiers
EmulsifiersEmulsifiers
Emulsifiers
 
An overview of encapsulation technologies for food
An overview of encapsulation technologies for foodAn overview of encapsulation technologies for food
An overview of encapsulation technologies for food
 
Troubleshooting in Distillation Columns
Troubleshooting in Distillation ColumnsTroubleshooting in Distillation Columns
Troubleshooting in Distillation Columns
 
Evaporator performance
Evaporator performanceEvaporator performance
Evaporator performance
 
spray drying
spray dryingspray drying
spray drying
 
Design and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation ColumnsDesign and Simulation of Continuous Distillation Columns
Design and Simulation of Continuous Distillation Columns
 
Mixing of liquids, solids and high viscosity materials
Mixing of liquids, solids and high viscosity materialsMixing of liquids, solids and high viscosity materials
Mixing of liquids, solids and high viscosity materials
 
invert sugar syrup.pptx
invert sugar syrup.pptxinvert sugar syrup.pptx
invert sugar syrup.pptx
 
Batch Distillation
Batch DistillationBatch Distillation
Batch Distillation
 
Distillation Column
Distillation ColumnDistillation Column
Distillation Column
 
Advance in mass transfer in food application
Advance in mass transfer in food applicationAdvance in mass transfer in food application
Advance in mass transfer in food application
 
Confectioneries - Food Technology
Confectioneries - Food TechnologyConfectioneries - Food Technology
Confectioneries - Food Technology
 
extrusion
extrusion extrusion
extrusion
 
Chapter 4a heavy_oil2
Chapter 4a heavy_oil2Chapter 4a heavy_oil2
Chapter 4a heavy_oil2
 
Agitation & mixing presentation, group d
Agitation & mixing presentation, group dAgitation & mixing presentation, group d
Agitation & mixing presentation, group d
 
Filtration
FiltrationFiltration
Filtration
 

Viewers also liked

Principles, Classification and Selection of Solar Dryers
Principles, Classification and Selection of Solar DryersPrinciples, Classification and Selection of Solar Dryers
Principles, Classification and Selection of Solar DryersiMentor Education
 
Project on mango juice industry Ltd.
Project on mango juice industry Ltd.Project on mango juice industry Ltd.
Project on mango juice industry Ltd.Md Mir Belal
 
17219649 project-report-ashwani
17219649 project-report-ashwani17219649 project-report-ashwani
17219649 project-report-ashwaniramadevu
 
design-fabrication-solar food dryer
design-fabrication-solar food dryerdesign-fabrication-solar food dryer
design-fabrication-solar food dryerSuchit Moon
 
Technology of milk products Dry Milk powder presentation
Technology of milk products Dry Milk powder presentationTechnology of milk products Dry Milk powder presentation
Technology of milk products Dry Milk powder presentationDr.Sharon Abdul Jameela
 
PROJECT REPORT ON SOLAR DRYER
PROJECT REPORT ON SOLAR DRYERPROJECT REPORT ON SOLAR DRYER
PROJECT REPORT ON SOLAR DRYERAnugrah Soy
 
Spray drying pre lab report ppt final
Spray drying pre lab report ppt finalSpray drying pre lab report ppt final
Spray drying pre lab report ppt finalHazel Katipunan
 
Imbibition dynamics in interacting capillaries
Imbibition dynamics in interacting capillariesImbibition dynamics in interacting capillaries
Imbibition dynamics in interacting capillariesiMentor Education
 
Pressure Relief Systems Vol 2
Pressure Relief Systems   Vol 2Pressure Relief Systems   Vol 2
Pressure Relief Systems Vol 2Gerard B. Hawkins
 
Open Source Creativity
Open Source CreativityOpen Source Creativity
Open Source CreativitySara Cannon
 
Milk and milk products
Milk and milk productsMilk and milk products
Milk and milk productsEkta Belwal
 

Viewers also liked (15)

Principles, Classification and Selection of Solar Dryers
Principles, Classification and Selection of Solar DryersPrinciples, Classification and Selection of Solar Dryers
Principles, Classification and Selection of Solar Dryers
 
Amputation of tail in cat
Amputation of tail in catAmputation of tail in cat
Amputation of tail in cat
 
Project on mango juice industry Ltd.
Project on mango juice industry Ltd.Project on mango juice industry Ltd.
Project on mango juice industry Ltd.
 
17219649 project-report-ashwani
17219649 project-report-ashwani17219649 project-report-ashwani
17219649 project-report-ashwani
 
design-fabrication-solar food dryer
design-fabrication-solar food dryerdesign-fabrication-solar food dryer
design-fabrication-solar food dryer
 
Technology of milk products Dry Milk powder presentation
Technology of milk products Dry Milk powder presentationTechnology of milk products Dry Milk powder presentation
Technology of milk products Dry Milk powder presentation
 
PROJECT REPORT ON SOLAR DRYER
PROJECT REPORT ON SOLAR DRYERPROJECT REPORT ON SOLAR DRYER
PROJECT REPORT ON SOLAR DRYER
 
Spray drying pre lab report ppt final
Spray drying pre lab report ppt finalSpray drying pre lab report ppt final
Spray drying pre lab report ppt final
 
Imbibition dynamics in interacting capillaries
Imbibition dynamics in interacting capillariesImbibition dynamics in interacting capillaries
Imbibition dynamics in interacting capillaries
 
Solar food drying
Solar food drying Solar food drying
Solar food drying
 
Solar dryer
Solar dryerSolar dryer
Solar dryer
 
Pressure Relief Systems Vol 2
Pressure Relief Systems   Vol 2Pressure Relief Systems   Vol 2
Pressure Relief Systems Vol 2
 
Mango's PowerPoint
Mango's PowerPointMango's PowerPoint
Mango's PowerPoint
 
Open Source Creativity
Open Source CreativityOpen Source Creativity
Open Source Creativity
 
Milk and milk products
Milk and milk productsMilk and milk products
Milk and milk products
 

Similar to Spray Drying

Design and Rating of Trayed Distillation Columns
Design and Rating  of Trayed Distillation ColumnsDesign and Rating  of Trayed Distillation Columns
Design and Rating of Trayed Distillation ColumnsGerard B. Hawkins
 
The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor Gerard B. Hawkins
 
Reciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case ExplosionsReciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case ExplosionsGerard B. Hawkins
 
How to Use the GBHE Mixing Guides
How to Use the GBHE Mixing GuidesHow to Use the GBHE Mixing Guides
How to Use the GBHE Mixing GuidesGerard B. Hawkins
 
Mixing of Gas Liquid Systems
Mixing of Gas Liquid SystemsMixing of Gas Liquid Systems
Mixing of Gas Liquid SystemsGerard B. Hawkins
 
Fixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up ChecklistFixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up ChecklistGerard B. Hawkins
 
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
 
Liquid Liquid Extraction - Basic Principles
Liquid Liquid Extraction - Basic PrinciplesLiquid Liquid Extraction - Basic Principles
Liquid Liquid Extraction - Basic PrinciplesGerard B. Hawkins
 
Fixed Bed Adsorber Design Guidelines
Fixed Bed Adsorber Design GuidelinesFixed Bed Adsorber Design Guidelines
Fixed Bed Adsorber Design GuidelinesGerard B. Hawkins
 
Distillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat IntegrationDistillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat IntegrationGerard B. Hawkins
 
Data Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction EquilibriaData Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction EquilibriaGerard B. Hawkins
 
Use and Applications of Membranes
Use and Applications of MembranesUse and Applications of Membranes
Use and Applications of MembranesGerard B. Hawkins
 

Similar to Spray Drying (20)

Centrifugation
CentrifugationCentrifugation
Centrifugation
 
Fluid Separation
Fluid SeparationFluid Separation
Fluid Separation
 
Design and Rating of Trayed Distillation Columns
Design and Rating  of Trayed Distillation ColumnsDesign and Rating  of Trayed Distillation Columns
Design and Rating of Trayed Distillation Columns
 
Pressure Systems
Pressure SystemsPressure Systems
Pressure Systems
 
Hydrogen Compressors
Hydrogen CompressorsHydrogen Compressors
Hydrogen Compressors
 
The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor
 
Reciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case ExplosionsReciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case Explosions
 
How to Use the GBHE Mixing Guides
How to Use the GBHE Mixing GuidesHow to Use the GBHE Mixing Guides
How to Use the GBHE Mixing Guides
 
Mixing of Gas Liquid Systems
Mixing of Gas Liquid SystemsMixing of Gas Liquid Systems
Mixing of Gas Liquid Systems
 
Sedimentation
SedimentationSedimentation
Sedimentation
 
Gas Mixing
Gas MixingGas Mixing
Gas Mixing
 
Fixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up ChecklistFixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up Checklist
 
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
 
Laboratory Distillation
Laboratory DistillationLaboratory Distillation
Laboratory Distillation
 
Liquid Liquid Extraction - Basic Principles
Liquid Liquid Extraction - Basic PrinciplesLiquid Liquid Extraction - Basic Principles
Liquid Liquid Extraction - Basic Principles
 
Fixed Bed Adsorber Design Guidelines
Fixed Bed Adsorber Design GuidelinesFixed Bed Adsorber Design Guidelines
Fixed Bed Adsorber Design Guidelines
 
High Shear Mixers
High Shear MixersHigh Shear Mixers
High Shear Mixers
 
Distillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat IntegrationDistillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat Integration
 
Data Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction EquilibriaData Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction Equilibria
 
Use and Applications of Membranes
Use and Applications of MembranesUse and Applications of Membranes
Use and Applications of Membranes
 

More from Gerard B. Hawkins

GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy GasesGAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy GasesGerard B. Hawkins
 
101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer - Best Practices GuideGerard B. Hawkins
 
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...Gerard B. Hawkins
 
Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming Gerard B. Hawkins
 
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...Gerard B. Hawkins
 
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSSTEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSGerard B. Hawkins
 
Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption:  Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption: Gerard B. Hawkins
 
Calculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel GasCalculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel GasGerard B. Hawkins
 
Piping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning ProcedurePiping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning ProcedureGerard B. Hawkins
 
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...Gerard B. Hawkins
 
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...Gerard B. Hawkins
 
Getting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen PlantGetting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
 
EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS Gerard B. Hawkins
 
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...Gerard B. Hawkins
 
Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción Gerard B. Hawkins
 
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
 
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Gerard B. Hawkins
 
GBHE Over View jan_13_español
GBHE Over View jan_13_españolGBHE Over View jan_13_español
GBHE Over View jan_13_españolGerard B. Hawkins
 

More from Gerard B. Hawkins (20)

Pressure Relief Systems
Pressure Relief Systems Pressure Relief Systems
Pressure Relief Systems
 
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy GasesGAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
 
101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide
 
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
 
Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming
 
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...
 
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSSTEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
 
Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption:  Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption:
 
Calculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel GasCalculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel Gas
 
Pickling & Passivation
Pickling & PassivationPickling & Passivation
Pickling & Passivation
 
Piping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning ProcedurePiping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning Procedure
 
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
 
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
 
Getting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen PlantGetting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen Plant
 
EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS
 
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...
 
Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción
 
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide
 
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
 
GBHE Over View jan_13_español
GBHE Over View jan_13_españolGBHE Over View jan_13_español
GBHE Over View jan_13_español
 

Recently uploaded

What Developers Need to Unlearn for High Performance NoSQL
What Developers Need to Unlearn for High Performance NoSQLWhat Developers Need to Unlearn for High Performance NoSQL
What Developers Need to Unlearn for High Performance NoSQLScyllaDB
 
Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024D Cloud Solutions
 
AI-based audio transcription solutions (IDP)
AI-based audio transcription solutions (IDP)AI-based audio transcription solutions (IDP)
AI-based audio transcription solutions (IDP)KapilVaidya4
 
Neo4j: Data Engineering for RAG (retrieval augmented generation)
Neo4j: Data Engineering for RAG (retrieval augmented generation)Neo4j: Data Engineering for RAG (retrieval augmented generation)
Neo4j: Data Engineering for RAG (retrieval augmented generation)Neo4j
 
Dev Dives: Master advanced authentication and performance in Productivity Act...
Dev Dives: Master advanced authentication and performance in Productivity Act...Dev Dives: Master advanced authentication and performance in Productivity Act...
Dev Dives: Master advanced authentication and performance in Productivity Act...UiPathCommunity
 
Deliver Latency Free Customer Experience
Deliver Latency Free Customer ExperienceDeliver Latency Free Customer Experience
Deliver Latency Free Customer ExperienceOpsTree solutions
 
Empowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership BlueprintEmpowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership BlueprintMahmoud Rabie
 
Future Research Directions for Augmented Reality
Future Research Directions for Augmented RealityFuture Research Directions for Augmented Reality
Future Research Directions for Augmented RealityMark Billinghurst
 
COMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online CollaborationCOMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online Collaborationbruanjhuli
 
20200723_insight_release_plan
20200723_insight_release_plan20200723_insight_release_plan
20200723_insight_release_planJamie (Taka) Wang
 
Cloud Revolution: Exploring the New Wave of Serverless Spatial Data
Cloud Revolution: Exploring the New Wave of Serverless Spatial DataCloud Revolution: Exploring the New Wave of Serverless Spatial Data
Cloud Revolution: Exploring the New Wave of Serverless Spatial DataSafe Software
 
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdfIaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdfDaniel Santiago Silva Capera
 
Videogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdfVideogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdfinfogdgmi
 
Linked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond OntologiesLinked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond OntologiesDavid Newbury
 
Tracking license compliance made easy - intro to Grant (OSS)
Tracking license compliance made easy - intro to Grant (OSS)Tracking license compliance made easy - intro to Grant (OSS)
Tracking license compliance made easy - intro to Grant (OSS)Anchore
 
Crea il tuo assistente AI con lo Stregatto (open source python framework)
Crea il tuo assistente AI con lo Stregatto (open source python framework)Crea il tuo assistente AI con lo Stregatto (open source python framework)
Crea il tuo assistente AI con lo Stregatto (open source python framework)Commit University
 
LLM Threats: Prompt Injections and Jailbreak Attacks
LLM Threats: Prompt Injections and Jailbreak AttacksLLM Threats: Prompt Injections and Jailbreak Attacks
LLM Threats: Prompt Injections and Jailbreak AttacksThien Q. Tran
 
KubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCost
KubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCostKubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCost
KubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCostMatt Ray
 
Building AI-Driven Apps Using Semantic Kernel.pptx
Building AI-Driven Apps Using Semantic Kernel.pptxBuilding AI-Driven Apps Using Semantic Kernel.pptx
Building AI-Driven Apps Using Semantic Kernel.pptxUdaiappa Ramachandran
 
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAAnypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAshyamraj55
 

Recently uploaded (20)

What Developers Need to Unlearn for High Performance NoSQL
What Developers Need to Unlearn for High Performance NoSQLWhat Developers Need to Unlearn for High Performance NoSQL
What Developers Need to Unlearn for High Performance NoSQL
 
Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024
 
AI-based audio transcription solutions (IDP)
AI-based audio transcription solutions (IDP)AI-based audio transcription solutions (IDP)
AI-based audio transcription solutions (IDP)
 
Neo4j: Data Engineering for RAG (retrieval augmented generation)
Neo4j: Data Engineering for RAG (retrieval augmented generation)Neo4j: Data Engineering for RAG (retrieval augmented generation)
Neo4j: Data Engineering for RAG (retrieval augmented generation)
 
Dev Dives: Master advanced authentication and performance in Productivity Act...
Dev Dives: Master advanced authentication and performance in Productivity Act...Dev Dives: Master advanced authentication and performance in Productivity Act...
Dev Dives: Master advanced authentication and performance in Productivity Act...
 
Deliver Latency Free Customer Experience
Deliver Latency Free Customer ExperienceDeliver Latency Free Customer Experience
Deliver Latency Free Customer Experience
 
Empowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership BlueprintEmpowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership Blueprint
 
Future Research Directions for Augmented Reality
Future Research Directions for Augmented RealityFuture Research Directions for Augmented Reality
Future Research Directions for Augmented Reality
 
COMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online CollaborationCOMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online Collaboration
 
20200723_insight_release_plan
20200723_insight_release_plan20200723_insight_release_plan
20200723_insight_release_plan
 
Cloud Revolution: Exploring the New Wave of Serverless Spatial Data
Cloud Revolution: Exploring the New Wave of Serverless Spatial DataCloud Revolution: Exploring the New Wave of Serverless Spatial Data
Cloud Revolution: Exploring the New Wave of Serverless Spatial Data
 
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdfIaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
 
Videogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdfVideogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdf
 
Linked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond OntologiesLinked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond Ontologies
 
Tracking license compliance made easy - intro to Grant (OSS)
Tracking license compliance made easy - intro to Grant (OSS)Tracking license compliance made easy - intro to Grant (OSS)
Tracking license compliance made easy - intro to Grant (OSS)
 
Crea il tuo assistente AI con lo Stregatto (open source python framework)
Crea il tuo assistente AI con lo Stregatto (open source python framework)Crea il tuo assistente AI con lo Stregatto (open source python framework)
Crea il tuo assistente AI con lo Stregatto (open source python framework)
 
LLM Threats: Prompt Injections and Jailbreak Attacks
LLM Threats: Prompt Injections and Jailbreak AttacksLLM Threats: Prompt Injections and Jailbreak Attacks
LLM Threats: Prompt Injections and Jailbreak Attacks
 
KubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCost
KubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCostKubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCost
KubeConEU24-Monitoring Kubernetes and Cloud Spend with OpenCost
 
Building AI-Driven Apps Using Semantic Kernel.pptx
Building AI-Driven Apps Using Semantic Kernel.pptxBuilding AI-Driven Apps Using Semantic Kernel.pptx
Building AI-Driven Apps Using Semantic Kernel.pptx
 
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAAnypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
 

Spray Drying

  • 1. GBH Enterprises, Ltd. Process Engineering Guide: GBHE-PEG-DRY-006 Spray Drying Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the information for its own particular purpose. GBHE gives no warranty as to the fitness of this information for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 2. Process Engineering Guide: Spray Drying CONTENTS SECTION 0 INTRODUCTION/PURPOSE 2 1 SCOPE 2 2 FIELD OF APPLICATION 2 3 DEFINITIONS 2 4 BACKGROUND TO TEST FACILITIES 3 5 DESIGN PROCEDURE 4 6 TEMPERATURE SENSITIVE PRODUCTS 4 7 FEEDSTOCK PREPARATION 5 8 FEEDSTOCK ATOMIZATION 5 9 PRODUCT COLLECTION 5 10 SAFETY ASPECTS 5 11 MICROSTRUCTURE OF DRIED PARTICLES 6 12 HYBRID DRYERS 6 13 BIBLIOGRAPHY 6 APPENDIX A CONTENTS LIST FOR SPS DRYING MANUAL VOLUME V PART 1 7 DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE 10 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 3. 0 INTRODUCTION/PURPOSE Spray drying is a relatively expensive method of drying, but is particularly recommended when the product is temperature-sensitive (due to the very short time that the product experiences elevated temperatures) or if the typical physical form of a spray dried product (spheroids with a median diameter of up to 250 micron) is desirable. Another advantage of spray drying is that it produces a very homogeneous product from multi-component feedstocks. A prerequisite is that the feed can be pumped and atomized. Spray drying, with co-current air/feedstock flow, is used extensively within some companies for drying specialty products (dyes, pigments, intermediates, surfactants, ceramics, biodegradable polymer). Target moisture contents down to about 0.1% can be achieved if the feedstock is a dispersion with little or no material in solution. However as the proportion of dissolved material increases, and particularly when that material can form a skin on drying, then realistic target moisture contents increase. With typical dyestuff formulations it is difficult to achieve moisture contents less than 2%, and a typical target moisture would be 4 to 5%. If very low moisture contents are required, then a counter-current design of spray dryer could be considered where almost dry particles experience the highest air temperatures. However this mode of operation is not suitable for temperaturesensitive products. Alternatively, a combination of co-current spray drying and e.g. fluid bed drying should be considered. 1 SCOPE This Guide deals with spray drying including the need for trials and the availability of test facilities. 2 FIELD OF APPLICATION This Guide applies to process engineers in GBHE Enterprises worldwide. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 4. 3 DEFINITIONS For the purposes of this Guide, the following definition applies: SPS The Separation Processes Service (SPS) is a research and consultancy organization, based at Harwell and Warren Spring Laboratory. It is active in the main operations related to separation, including comprehensive coverage of drying. With the exception of terms used as proper nouns or titles, those terms with initial capital letters which appear in this document and are not defined above are defined in the Glossary of Engineering Terms. 4 BACKGROUND TO TEST FACILITIES When spray drying is identified as a possible method of drying a material, trials are carried out in-house on pilot plant facilities and also on manufacturers' test facilities to confirm that spray drying is a suitable technique for the feedstock. The smallest (laboratory scale and 0.8 metre diameter Niro Mobile Minor) spray dryers will give some idea of whether a feedstock will spray dry, but a negative result should not necessarily preclude the use of a full scale spray dryer. The Niro Production Minor dryer (1.2 metre diameter) is the smallest scale recommended to give indications of potential problems such as adherence of product to ducting walls etc. However even at this scale the particle size is unlikely to be as big as that required from a full scale dryer and the product may not be representative of product from a full scale dryer, e.g. in terms of dispensability. Large scale trials are necessary to check the quality of the spray dried product and to give some guidance of the likely size of installation necessary to achieve the desired production rate. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 5. European Manufacturer, trial facilities: (a) Lab-scale dryers (b) Niro Mobile Minor (c) Niro Production Minor (d) Larger scale dryers There are a limited number of reputable suppliers of spray drying equipment. In Western Europe, the main suppliers are: (1) Niro Atomizer A/S Denmark (2) APV Pasilac Anhydro A/ Denmark (3) Drytec Ltd Tonbridge, Kent , U.K. (4) Barr and Murphy Overseas Ltd Maidenhead, Berks, U.K. 5 DESIGN PROCEDURE A design procedure for co-current spray dryers is given in Ref. [1] (the contents of which are listed in Appendix A), produced by SPS. Copies of Ref. [1] and may be ordered from SPS. A design procedure is included in Ref. [2]. SPS also provide several software packages (SPRY1, SPRY2A, SPRY2B, SPRY2C) to perform moisture and energy balances and preliminary sizing calculations for co-current spray dryers with a variety of different heating methods (direct and indirect firing, once-through versus total recycle of the drying gas). These are described in Ref. [3]. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 6. 6 TEMPERATURE SENSITIVE PRODUCTS While spray drying is recommended for the drying of temperature-sensitive products, there is evidence that some designs of spray dryer ("tower" dryers, i.e. tall, narrow types designed for nozzle atomization) are better than others (squat form types designed for rotary atomizers). The reason is believed to be that in the squat form types, the large gas recirculation zones entrain particles (particularly the smaller ones) which therefore have prolonged residence times and become over dried. Such recirculation zones are likely to be much smaller in tower dryers. 7 FEEDSTOCK PREPARATION Feedstock preparation is discussed in, “Paste Preparation Systems for Dryers”. Some additional comments are given below: (a) Spray dryers have to have a feedstock which is fluid enough to pump to the atomizer. With dispersion feedstocks, particularly when the particles have a high aspect ratio, the limiting total solids content for a pumpable feedstock may be less than 20%. The addition of a small amount of a suitable surfactant, where this is permitted in the dry product, can greatly increase the pumpable concentration. (b) If the concentration of the feedstock is such that a small increase in total solids (e.g. by 1 or 2%) would cause a large increase in viscosity, this could interfere with the atomization process to give strands rather than droplets, and the feedstock concentration should be reduced. (c) With feedstocks containing dispersed particles, there is an upper limit to the size of these particles beyond which blockage problems arise. This upper size limit is smaller for nozzle atomizers, which have narrow channels which the feed has to negotiate, than for rotary atomizers. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 7. 8 FEEDSTOCK ATOMISATION A key aspect of spray drying is atomization of the feedstock. Atomization is covered in Ref. [5] “Atomization in Spray Dryers (Operational Manual)”, GBHE recommends mainly pressure nozzles and rotary atomizers, and to a limited extent the use of fluid nozzles. Work is underway to develop novel atomizers for spray drying, to give narrower drop size distributions and hence less dusty products. The narrower drop size distributions are likely to reduce the extent of entrainment in recirculation zones which causes prolonged residence times in the dryer. 9 PRODUCT COLLECTION Product leaves the dryer both from the rotary valve in the base of the drying chamber and from the drying air exhaust stream. The particle size distribution in the rotary valve will be coarser than in the exhaust stream. Use is often made of this classification effect to reduce the dustiness of the product, by collecting only the product from the chamber for further use or sales, while the fines in the air stream are separated off and recycled, usually by re-dispersing in the feedstock. Separation of the fines from the air stream is usually carried out by cyclone, though bag filters are used for some products where there is a high proportion of very fine particles. 10 SAFETY ASPECTS By their nature, spray drying facilities pose a risk of dust cloud explosions. The risk of explosions or fires is minimized by: (a) The use of operating conditions, particularly maximum air inlet temperatures, defined from appropriate flammability and explosion severity tests. In extreme cases, it may be necessary to operate with inert drying gas in a closed cycle. (b) Minimizing build-up of dried product in the dryer and associated ductwork. Use is often made of automatic hammers on the dryer chamber to disturb product adhering to the chamber wall. (c) The use of explosion suppression equipment where appropriate. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 8. Explosion suppression equipment is not appropriate for large spray dryer chambers and so these are normally fitted with explosion relief panels to vent any explosion, thereby avoiding major damage. The subject of fire and explosion hazards in dryers is covered by GBHE-PEGDRY-005 and Ref. [6]. Where the product is toxic, the dusty nature of spray dried products poses particular problems both in terms of the obvious need to protect operators from exposure to the product and also the less obvious fact that, in the event of an explosion, the opening of relief panels allowing the toxic product to be blown into the environment might not be acceptable. 11 MICROSTRUCTURE OF DRIED PARTICLES The quality of spray dried products can be affected by the microstructure of the dried particles. This is controlled mainly by the nature of the feedstock, and to a lesser extent by the drying conditions. The relationship between particle microstructure and feedstock is discussed in “Spray Drying: The Qualitative Effect of Factors Governing the Packing Density and Dustiness of Spray Dried Products”, W M L Wood (1987). An awareness of this relationship can influence the range of feedstock parameters and drying conditions to be used, which in turn can influence the final design and size. 12 HYBRID DRYERS In addition to conventional spray dryers, hybrid dryer systems are offered by some manufacturers. Such systems combine spray drying with fluid bed drying. Several manufacturers design systems with a separate fluid bed fed from the spray dryer. Niro offer a single unit, their FSD dryer, in which a fluid bed dryer is incorporated in the base of a co-current spray dryer. Such units offer improved thermal efficiency and, particularly in the case of the FSD, the opportunity to produce a granulated product with reduced dust content. The design of combined systems with a fluid bed dryer following a spray dryer can be achieved using the design guides for the individual dryer types, and optimizing the thermal efficiency by choosing appropriate moisture contents for the product exiting the spray dryer and entering the fluid bed. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 9. 13 BIBLIOGRAPHY [1] Drying Manual, Volume V (Spray Drying) Part 1, SPS, Harwell [2] Industrial Drying Equipment - Selection and Application, C M van't Land, Marcel Dekker (1991) [3] Drying Manual, Volume V (Spray Drying) Parts 3 and 4, SPS, Harwell. [4] The Spray Drying Handbook, 5th edition, K Masters, Longman (1992). [5] Drying Manual, Volume V (Spray Drying) Part 2, SPS, Harwell [6] The Prevention of Fires and Explosions in Drying, 2nd edition, J Abbott, IChemE, (1991). Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 10. APPENDIX A CONTENTS LIST FOR SPS DRYING MANUAL VOLUME V PART 1 (A Practical Guide to Selection and Design of Spray dryers) Page No 1 INTRODUCTION 1.7 1.1 1.2 1.3 Background and purpose Scope and limitations Report format 1.7 1.7 1.7 2 DESIGN GUIDE 1.9 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Preliminary examination of data Rough sizing on basis of air throughput Flowsheet considerations Atomization method and chamber diameter Chamber selection Other considerations and design methods available Programmable calculator program (Texas T159) Psychrometric chart calculations Example calculation illustrating psychrometric chart design method 2.9.1 Specification of requirements 2.9.2 Solution procedure 1.9 1.9 1.9 1.9 1.11 1.11 1.11 1.14 3 FLOWSHEET CONSIDERATIONS 1.24 3.1 3.2 Is the liquid to be removed water or some other material? Is there any volatile material present in the feed other than water or solvent that is likely to cause problems? Is the product or solvent toxic, carcinogenic, irritating or the like? Is the product a dust explosion risk? Does the product suffer from exposure to oxygen at drying temperatures? Is the product sensitive to products of combustion? Is the product permanently damaged by heat within the exposure times applying in spray dryers? Can the dried product be sticky, or suffer temporary thermal damage? 1.24 3.3 3.4 3.5 3.6 3.7 3.8 1.17 1.17 1.17 1.24 1.24 1.24 1.25 1.25 1.25 1.26 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 11. 3.9 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 Is there a maximum temperature for final discharged product? Could the final product be discharged with advantage at a single point other than at the dryer itself? Is the spray dryer the first stage of a multi-stage drying system? Is product particle size classification necessary or desirable? Is heat available from an external source? What are the limits on emissions to atmosphere? Is heat recovery from dryer exhaust desirable? Can the product foam in water/solvent? Can the feed liquid foam? 1.28 Are there acoustic limits to be met? Must special attention be paid to hygiene and cleanability? 4 CAPACITY CONSIDERATIONS 1.29 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Agreement on required capacity Evaporative load variations Effects of transient and abnormal conditions Shutdown and cleaning outages Periodic maintenance requirements Maintenance of efficient operating conditions Effect of product properties Plants for multiple products Feedstock concentration 1.29 1.29 1.29 1.29 1.29 1.30 1.30 1.30 1.30 5 ATOMIZATION CHARACTERISTICS AND SELECTION 1.32 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 Methods available Centrifugal atomizers Pressure nozzles Pneumatic (two-fluid) nozzles Maximum particle size in feedstock Spray-air mixing Cost comparison Product granulometry Erosion problems Use of multiple atomizers Design choices Size distribution of spray droplets 1.32 1.33 1.33 1.33 1.33 1.33 1.33 1.34 1.34 1.34 1.34 1.34 3.10 3.11 1.26 1.26 1.27 1.27 1.27 1.27 1.28 1.28 1.28 1.28 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 12. 5.13 5.14 5.15 Atomizer selection Re-examination of product specification Atomizer choice (summary) 1.36 1.36 1.36 6 DRYING CHAMBERS 1.37 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 Introduction Box-type dryers Cylindrical dryers Choices in chamber design parameters Chamber designs commonly used Applications of various chamber designs Selection of standard size and shape Definition of chamber volume facto Effect of atomization and airflow on chamber design Prevention and removal of deposits from chamber walls Floor sweepers for flat-bottomed chambers Designing for explosion risks in the dryer Largest median particle size for given chamber diameter Consideration of gas residence time in chamber sizing 1.37 1.37 1.37 1.37 1.40 1.40 1.41 1.41 1.41 1.43 1.43 1.43 1.44 1.44 7 SELECTION OF DESIGN PARAMETERS 1.45 7.1 Fixed design data 7.2 Parameters which may be varied 7.3 Detailed consideration of design variables 7.3.1 Flowsheet 7.3.2 Oxygen level 7.3.3 Condenser temperature 7.3.4 Inert gas 7.3.5 Partial recycle of exhaust gas without condensation 7.3.6 Heating means 7.3.7 Wet recycle of fines 7.3.8 Scrubber liquor 7.3.9 Cold air additions 7.3.10 Floor sweeper air 7.3.11 Atomization 7.3.12 Dryer air inlet temperature 7.3.13 Dryer air outlet temperature 7.3.14 Residence time 7.4 Design data questionnaire 1.45 1.45 1.45 1.46 1.46 1.46 1.46 1.46 1.47 1.47 1.47 1.47 1.48 1.48 1.48 1.49 1.51 1.55 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 13. NOMENCLATURE 1.58 REFERENCES 1.59 APPENDICES App. A.1 A.1.1 A.1.2 A.1.3 A.1.4 A.1.5 A.2 A.2.1 A.2.2 Derivation of equations in Chapter 2 Equation (2.1) Equation (2.3) Equation (2.7 Equation (2.4) Equation (2.2) Calculator program for Texas TI59 Program equations Program listing 1.60 1.60 1.60 1.61 1.61 1.61 1.63 1.63 1.64 TABLES Table 2.1 2.2 5.1 6.1 6.2 7.1 Values of fuel moisture rate, fmr Psychrometric chart data state Major characteristics of atomizers Volume factors for dryer chambers Recommended chamber shapes Drying conditions used on some products 1.13 1.15 1.32 1.41 1.42 1.53 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 14. ILLUSTRATIONS Fig 2.1 2.2 2.3 2.4 2.5 5.1 5.2 6.1 6.2 7.1 7.2 Computer program results Psychrometric chart for once-through, direct-fired dryer example Psychrometric chart showing effect of cold air addition Psychrometric chart for direct-fired system with partial exhaust recycle Psychrometric chart showing effect of an exhaust gas scrubber Typical product particle size distribution for three atomizer types Extreme and typical product particle size ranges for three different atomizer types Chambers for centrifugal atomizers Chambers for nozzle atomizers Relationship between product moisture content and air outlet temperature Typical dryer design data questionnaire 1.14 1.20 1.21 1.22 1.23 1.35 1.35 1.38 1.39 1.50 1.56 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 15. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com