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Chemical Engineering Design of The Spray Dryer

This document details the design of a spray dryer system. It describes the process of spray drying which converts liquid feed into a dry powder using hot air. It then outlines the design calculations and parameters considered, such as feed rate, temperatures, densities, and viscosities. Based on these inputs, it selects design parameters for the rotary atomizer including wheel diameter, speed, number of vanes, and vane height. Using these parameters and calculations for droplet size and operating velocity, it then designs the dimensions of the spray drying chamber, including column diameter, cylindrical height, conical height and angle. Residence time and dryer efficiency are also calculated.

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5K views6 pages

Chemical Engineering Design of The Spray Dryer

This document details the design of a spray dryer system. It describes the process of spray drying which converts liquid feed into a dry powder using hot air. It then outlines the design calculations and parameters considered, such as feed rate, temperatures, densities, and viscosities. Based on these inputs, it selects design parameters for the rotary atomizer including wheel diameter, speed, number of vanes, and vane height. Using these parameters and calculations for droplet size and operating velocity, it then designs the dimensions of the spray drying chamber, including column diameter, cylindrical height, conical height and angle. Residence time and dryer efficiency are also calculated.

Uploaded by

victor
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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CHEMICAL ENGINEERING DESIGN OF THE SPRAY DRYER

The Chemical Engineering design of the Spray dryer involves determining the height and
diameter (dimensions) of the chamber that can adequately accommodate the mass of the plant
material.

Spray drying converts a liquid feed into dry powder by atomizing the feed into a stream of hot
air contained in a chamber of suitable geometry. Uniform drying, consistency of physical
properties, uniformity of size and shape are some of the notable advantages of this suspended-
air drying technique.

The design of the spray dryer was done using the following information based on calculations
of first semester;

M = Feed rate entering the dryer = 187410 kg/day

Mtomato = Mass of tomato entering the dryer = 5622.3 kg/day

Mwater = Mass of water entering the dryer = 181787.7 kg/day

T1 = Inlet temperature of air into the dryer =120oC

T2 = Outlet temperature of tomato powder =70oC

T0 = Inlet temperature of air =120oC

µ = viscosity of air at 120oC = 22.58 x 10-6 Pa.s (Engineering toolbox)

pf = density of air = 1.225 kg/m3

pt = density of tomato = 1.02g/cm3

g = acceleration due to gravity = 10m/s

DESIGN OF ROTARY ATOMIZER

For industrial rotary atomizer, Herring-Marshall equation can be used to predict parameter
values (Herring & Marshall). The basic parameters are the droplet size Dvm (volume mean
diameter) microns, feed rate ML kg/min, height of vanes h cm, rotation speed N rpm, diameter
of wheel d cm, number of vanes n. The equation is given as:
𝐾 (𝑀)0.24
Dvm =
(𝑁 𝑑)0.83 (𝑛 ℎ)0.12

The constant K for industrial dryers of large capacity is about 29.4 x 104. This correlation is
valid over the following ranges of parameters:

Variable Range of Operations


Wheel diameter (cm) 19.0 – 23.0
Wheel speed (rpm) 10000 - 18000
Mp = Liquid loading on vane 0.9 – 5.4

Where

𝑀
Mp = ( ) kg/min cm
𝑛ℎ

The design procedure consists simply of choosing reasonable values for d, n and h which will
result in 0.9 < Mp < 5.4.

The following set of design parameters is one of the numerous possible combinations suitable
for the specified duty.

Wheel diameter = 22.9cm; Wheel speed = 15 000 rpm; Number of vanes = 20; Height of
vanes = 1.9 cm

Therefore, M = 200000kg/day = 130.15kg/min

Mp = 3.425 and Dvm = 15.54µm = droplet diameter = 𝐷𝑝

SETTLING VELOCITY

The settling velocity of the particles in the spray dryer can be evaluated using the equation
below within the region where Stoke’s law is valid.

𝐷𝑝 2 (𝑝𝑡 − 𝑝𝑓 )𝑔
vs =
18µ

(15.54𝑥102 (𝑝𝑡 − 𝑝𝑓 )𝑔
=
18µ

vs = 6.0532x10-3m/s
OPERATING VELOCITY OF ATOMIZER

The operating velocity is taken as two times the settling velocity. This is also an estimate of
the mixture velocity at the send of the nozzle.

Operating velocity va = 2 x vs = 0.0121m/s or 1.21cm/s

SPRAY CHAMBER DESIGN

In order to fully design the spray drying chamber which has a cylindrical section attached to a
conical region at the base, certain features need to be specified

 Residence time
 Evaporation rate of water
 Heated gas flow rate
 Input and exit temperature of air
 Relative humidity

Once these specifications have been made, further analysis can be done to determine

 Column diameter
 Height of cylindrical portion
 Height of conical portion
 Cone angle

RESIDENCE TIME

The residence time of a spray dryer is the time taken for the drying operation to achieve its
desired moisture content in the spray chamber. According to Brown et al, residence time td is
given as

td = 50√𝑋1

X1 = mass ratio of water to tomato in feed = 0.031

Therefore td = 50√0.031 = 8.803s

DRYER EFFICIENCY

Overall thermal efficiency is given by


𝐻𝑒𝑎𝑡 𝑢𝑠𝑒𝑑 𝑖𝑛 𝑒𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛
Noverall =
𝐻𝑒𝑎𝑡 𝑖𝑛𝑝𝑢𝑡

𝑇1 − 𝑇2 120−70
=( ) x 100 = x 100
𝑇1 − 𝑇0 120−25

= 52.63%

CHAMBER DIMENSIONS

COLUMN DIAMETER

In order to determine the column diameter of a spray dryer chamber being designed it is
essential to determine the area of the vessel.

Column area = (Heated gas flow rate x Average humid volume)/ Operating velocity

Heated gas flow rate = Gs = 300kg/hr

Average humid volume = Vavg = 2.59m3/kg dry air

Therefore, Column Area = Ac = 17.837m2

The column diameter can be evaluated thus

4 𝑥 𝐴𝑐
Dc = √
𝜋

Column diameter = Dc = 4.77m

For safety considerations, 10% allowance is provided

Column diameter = 1.10Dc = 5.247m

VOLUME OF THE CHAMBER Vt

Vt = Volumetric flowrate of drying air x Residence time

Volumetric flowrate = 17.837m2 x 1.21m/s = 21.58m3/s

And residence time = 8.803s

Evaluating, Vt = 189.93m3
HEIGHT OF CYLINDRICAL PORTION OF CHAMBER hcyl

hcyl = 0.6 x Dc

hcyl = 0.6 x 5.247 = 3.148m

VOLUME OF CONICAL SECTION

The volume of the conical base of the spray dryer can be evaluated by subtracting the volume
of the upper cylinder from the total volume initially evaluated.

𝜋𝐷𝑐 2 ℎ𝑐𝑦𝑙
Vconc = Vt -
4

Vconc = 189.93-68.07 = 121.86m3

HEIGHT OF CONICAL PORTION OF CHAMBER hcone

3 𝑥 4 𝑥 𝑉𝑐𝑜𝑛𝑒
hconc =
𝜋𝐷𝑐 2

= 16.9m

CONE ANGLE

This measure of how much the conical region of the spray chamber tapers in.

𝛼 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑐ℎ𝑎𝑚𝑏𝑒𝑟 𝐷𝑐
tan ( ) =
2 𝑐𝑜𝑛𝑖𝑐𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 2ℎ𝑐𝑜𝑛𝑒

Cone angle = α = 17.65o


REFERENCES

A S Mujumdar and V Jog, A Simple Procedure for Design of a Spray Dryer, vol 57, 1977,
p1-4.

W M Herring and W R Marshall, American Institute of Chemical Engineering Journal, vol 1,


no 2, 1955, p 200.

https//:www.engineeringtoolbox.com

AKINJOLE SAMUEL

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