Spray Drying of Foods

Spray Drying of Foods
by
Prof.ArunS.Mujumdar
NationalUniversityofSingapore
InternationalWorkshoponDryingofFoodand
Biomaterials
Bangkok June67,2011
CONTENTS
DefinitionofSprayDrying
Advantagesandlimitationsofspraydrying
*Advantages
*Limitations
Classificationofspraydryers
Componentsofspraydryer
*Typesofatomization
*Flowpatterns
*Collectiontypes
*Controlmethods
Examplesofspraydrying
Sometypicalspraydryingprocesses
Developmentsinspraydrying
Closures
CONTENTS(continued)
Definition
a special process
which is used to
transform the feed
from a liquid state into
a dried particulate
form (Powder or
Particles) by spraying
the feed into a hot
drying medium.
Definition
Definition
Definition
Whatisspraydrying?
Hotair
Liquid
feed
Droplets
Moisture
Heat
Solid
formation
POWDER
Continuousandeasytocontrolprocess
Applicabletobothheatsensitiveandheat
resistantmaterials
Applicabletocorrosive,abrasive,toxicand
explosivematerials
Satisfiesaseptic/hygienicdryingconditions
Differentproducttypes:granules,agglomerates,
powdersetccanbeproduced
Differentsizesanddifferentcapacities
TheAdvantagesofSprayDrying
Highinstallationcost
Largeairvolumesatlowproductholdupimplies
gascleaningcostly
Lowerthermalefficiency
Heatdegradationpossibilityinhightemperature
spraydrying
TheLimitationsofSprayDrying
FigureTypicalspraydryerlayout
Aconventionalspraydryingprocessconsistsofthefollowingfourstages:
1.Atomizationoffeedintodroplets
2.Heatingofhotdryingmedium
3.Sprayaircontactanddryingofdroplets
4.Productrecoveryandfinalairtreatment
ComponentsofSprayDryingSystem
Advantages:
Handles large feed rates with single
wheelordisk
Suited for abrasive feeds with proper
design
Hasnegligiblecloggingtendency
Change of wheel rotary speed to control
theparticlesizedistribution
More flexible capacity (but with changes
powderproperties)
Limitations:
Higher energy consumption compared to
pressurenozzles
Moreexpensive
Broadspraypatternrequireslargedrying
chamberdiameter
Typesofatomizers:Rotaryatomizer
Advantages:
*Simple,compactandcheap
*Nomovingparts
*Lowenergyconsumption
Limitations:
*Lowcapacity(feedrateforsinglenozzle)
*Hightendencytoclog
*Erosioncanchangespraycharacteristics
Typesofatomizers:Pressurenozzle
Advantages:
*Simple,compactandcheap
*Nomovingparts
*Handlethefeedstocks withhighviscosity
*Produceproductswithverysmallsizeparticle
Limitations:
*Highenergyconsumption
*Lowcapacity(feedrate)
*Hightendencytoclog
Typesofatomizers:Pneumaticnozzle
CocurrentflowCountercurrentflowMixedcurrent
flow
TypesofSprayDryersflowpatterns:Cocurrentflow
PowderCollectors
SystemA:
Itmaintainstheoutlettemperaturebyadjustingthefeed
rate.Itisparticularlysuitableforcentrifugalspraydryers.
This control system usually has another control loop, i.e.,
controllingtheinlettemperaturebyregulatingairheater.
SystemB:
Itmaintainstheoutlettemperaturebyregulatingtheair
heater and keeping the constant spray rate. This system
can be particularly used for nozzle spray dryers, because
varyingsprayratewillresultinchangeofthedropletsize
distributionforpressureorpneumaticnozzle.
Controlsystems
SelectionTreeforSprayDryingSystem
SomeExamplesofSprayDryingSystems
17
Pr oduct Feed co
ncent r a
t i on %
Resi dua
l - moi s
t ur e %
Dr yi ng-
t emper at ur e (
0
C)
Spr ay dr yer desi gn
I nl et Out l et
Cof f ee 30- 55 2. 0- 4. 5 180-
250
80- 115 OCL; CCF; PNN; SS; CY; M
S
Egg 20- 24 3- 4. 5 180-
200
80- 90 OCL; CCF; CA/ PNN; SS; C
Y/ BF
Enzyme 20- 40 2. 0- 5. 0 100-
180
50- 100 OCL; CCF, CA/ PNN, SS; B
F/ CY+WC
Ski mmi l k 47- 52 3. 5- 4. 0 175-
240
75- 95 OCL; CCF; CA/ PNN; SS/ M
S CY/ BF
Spi r ul i na 10- 15 5. 0- 7. 0 150-
220
90- 100 OCL/ SCCL; CCF; CA; SS;
BF/ CY+WC
Mal t odext r i
n
2. 5- 6. 0 2. 5- 6. 0 150-
300
90- 100 OCL; CCF/ MF; PNN/ CA; S
S; BF/ CY+WC
Soya
pr ot ei n
12- 17 2. 0- 5. 0 175-
250
85- 100 OCL; CCF; PN; SS; BF
Tea ext r act 30- 40 2. 5- 5. 0 180-
250
90- 110 OCL; CCF; PN; SS; CY/ CY
+WC
Tomat o
past e
26- 48 3. 0- 3. 5 140-
160
75- 85 OCL; CCF; PN/ CA; SS/ MS;
CY/ BF
SprayDryingApplicationsinFoodTechnology
SomeBasicSprayDryingProcessesusedin
FoodProduction
SprayDryingofSkimMilk
MicrographofspraydriedSkimMilk
SprayDryingofTomatoJuice
SprayDryingofCoffee
DevelopingTrendsinSprayDrying
Oper at i on/ comput at i on par amet er s SD SD+VFB SD+I FB SD+I FB+VFB ( MSD)
Spr ay dr yi ng
I nl et ai r t emper at ur e (
0
C) 200 230 230 260
Ai r r at e ( kg/ h) 31500 31500 31500 31500
Spr ay r at e ( kg/ h) 2290 3510 4250 5540
Sol i d cont ent ( %) 48 48 48 48
Moi st ur e ( %DB) 108. 3 108. 3 108. 3 108. 3
Resi dual moi st ur e ( %) 3. 5 6 9 9
Out l et t emper at ur e (
0
C) 98 73 65 65
Evapor at i on r at e ( kg/ h) 1150 1790 2010 2620
Ener gy consumpt i on ( GJ) 7. 6 8. 86 8. 9 9. 95
Ener gy consumpt i on/ kg powder
( kJ/ kg)
6667 4949 3971 3428
VFB I FB I FB
Ai r r at e ( kg/ h) 4290 6750 11500
Ai r t emper at ur e (
0
C) 100 115 120
Evapor at i on r at e ( kg/ h) 45 125 165
Resi dual moi st ur e ( %) 3. 5 3. 5 3. 5
Ener gy consumpt i on ( GJ) 0. 48 0. 82 1. 11
Over al l dr yi ng per f or mance
Tot al ener gy consumpt i on ( GJ) 9 9. 34 9. 72 11. 1
Ener gy consump. / kg powder ( MJ/ kg) 6. 67 5. 35 4. 34 4. 01
Powder di amet er ( mi cr on) 50- 150 50- 200 50- 500 50- 500
Fl owabi l i t y poor Fr eef l ow
Fr eef l ow
Fr ee- f l ow
Bul k densi t y ( kg/ m
3
) ( Appr ox. ) 600 480 450 450
MultistageSprayDryingSystem
Advantages:
*Nofireandexplosionhazards
*Nooxidativedamage
* Ability to operate at vacuum and high operating pressure
conditions
*Easeofrecoveryoflatentheatsuppliedforevaporation
*Betterqualityproductundercertainconditions
*Closedsystemoperationtominimizeairpollution
Limitations:
*Higherproducttemperature
*Highercapitalcostscomparedtohotairdrying
* Possibility of air infiltration making heat recovery from
exhauststeamdifficultbycompressionorcondensation
SuperheatedSteamSprayDrying
Aschematic
flowchartofthe
conventionalspray
freezedrying
SprayFreezeDrying
Atpresent,ComputationalFluidDynamic
(CFD)ispopularinmodelingofspray
dryingprocesswiththecomputer
developing.
ModelingofSprayDrying
CFDmodelling anddepositionstudyof
spraydryers
Part1:Reductionofparticlewalldeposition
Part2:Evaluationofdropletdryingmodels
Part3:CFDanalysisofairflowstability
Part4:Newparticlewalldepositionmodel
Weblikedeposition
(gelatin)
Depositionattheconical
wall
(sucrosemaltodextrin)
Dripping
problem
(sucrose
maltodextrin)
Experimentstodeterminedepositionfluxes
Experimentstodeterminedepositionfluxes
0.14m
2
0.14m
2
0.15m
2
Findings
Middle plate
Bottom plate
0.005
0.01
0.015
0.02
0.025
100 120 140 160 180
Inlet temperature, C
D
e
p
o
s
i
t
i
o
n

f
l
u
x
,

g

m
-
2

s
-
1
SS
TF
0.01
0.015
0.02
0.025
0.03
100 120 140 160 180
Inlet temperature, C
D
e
p
o
s
i
t
i
o
n

f
l
u
x
,

g

m
-
2

s
-
1
SS
TF
Depositionstrengthtester
Airsparger
Adjustabledisperser
angle
Clipstohold
theplate
Quickcoupling
tocompressed
airline
Evaluated:ReactionEngineeringApproach (REA) vs
CharacteristicDryingCurve(CDC)
Comparedwithsingledropletdata(Adhikari etal.)
Hotdryingair
Glassfilament
Droplet
Axisymmetric model(FLUENT)
Steadystate
EulerLagrangian
Turbulence:RNGke
Includedmoisturetransport
UDF(Clanguage)formodels
Coupled(2
nd
orderaccuracy)
Airinlet
Outlet
1.75m
0.50m
0.70m
Trackedparticle
moistureasit
movesaround
Findings
REA
CDCmodified
Evaporationratefrom
particles,kgs
1
Deviation:Differentresponsetoinitialmoisture
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 0.5 1 1.5 2 2.5 3 3.5
Time, s
P
a
r
t
i
c
l
e

m
o
i
s
t
u
r
e
,

%
w
t
80 % wt moisture
60 %wt moisture
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 0.5 1 1.5 2 2.5 3 3.5
Time, s
P
a
r
t
i
c
l
e

m
o
i
s
t
u
r
e
,

%
w
t
90 % wt moisture
80 % wt moisture
70 % wt moisture
50 % wt moisture
REA CDC
Cottontuftvisualization
Hotwiremeasurments
Hot wire
Protective sheathe
Radialdirection
Circumference
direction
Inlet
Outlet
Axial
direction
0.7m
0.6m
(intopaper)
X
Z
Y
Findings:Jetfeedbackmechanism
Deflectionto
conicalwall
Upward
recirculation
atopposite
side
Findings:Effectofexpansionratio
20.16s
50.88s 100.32s
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0.5
1.0
1.5
2.0
Axialvelocity(ms
1
)
20.16s
Findings:Effectofexpansionratio
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0.5
1.0
1.5
2.0
5.28s 30.72s
Axialvelocity(ms
1
)
Part4:Newdepositionmodel
Bigchallengeasrigiditychanges
ProposedaViscoelastic approach
120Cinlet
Amorphousglass
190Cinlet
Amorphousrubbery
Viscoelastic contactmodelling
t d
d
E

+ =
Stress
Storage
coefficient
Strain Loss
coefficient
Stra
in
rate
Strongreboundandescape
(diameter:100m,initialvelocity:0.5ms
1
,TTg:23C)
Findings
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
15 17 19 21 23 25 27 29
TTg,C
R
e
s
t
i
t
u
t
i
o
n
f
a
c
t
o
r
0.2m/s
0.5m/s
1.0m/s
1.5m/s
Viscoelastic contactmodelling
Superposition technique
Storagemodulus
Lossmodulus
247 . 1
) ( 228 . 1 T A E =
056 . 1
) ( 235 T A E =

( )
T
A E
( )
T
A E

( )
T
A E
( )
T
A E

SomemoreCFDmodelling Work
Various tested geometries modeled by CFD
Example Specifications Remarks
Differentgeometry Conical, hourglass,
lantern, cylinder
oncone
New idealimited
experience
HorizontalSDZ Newdevelopment
Coffeespraydryer two nozzles
installed
Industrialscale
Conventional spray
dryer with rotary
disc
Cylinderoncone
geometry. Rotary
discatomizer
Conventional
concept firsttry
H
1
=820mm
H
2
=870mm
H
3
=70mm
H
4
=100mm
D
1
=935mm
D
3
=74mm
D
4
=170mm
D
5
=136mm
Cylinderoncone
Injection
position
Atthe
center
andH
4
away
fromthe
top
ceiling
ConicalChamber
H
0
=1690mm
D
1
=935mm
D
3
=74mm
Inletsizeis
sameasthat
inCaseK
Injection
position
Atthe
centerand
H
4
away
fromthe
topceiling
HourglassChamber
H
1
=820mm
H
2
=870mm
D
1
=935mm
D
2
=400mm
D
3
=74mm
Inletsizeis
sameas
thatinCase
K
Injection
position
Atthe
centerand
H
4
away
fromthe
topceiling
Lantern
chamber
H
1
=820mm
H
2
=870mm
D
1
=400mm
D
2
=935mm
D
3
=74mm
Inletsizeis
sameasthat
inCaseK
Injectio
n
position
Atthe
center
andH
4
away
fromthe
top
ceiling
Cylinderoncone
Conicalchamber
Novelspraydryergeometrytests
Novelspraydryergeometrytests
Thepossibilityofchangingthespraychambergeometrywasinvestigatedfor
better utilization of dryer volume and to obtain higher volumetric heat and
masstransferperformancecomparedtothetraditionalcocurrentcylinderon
coneconfiguration.
Thepredictedresultsshowthathourglassgeometryisaspecialcaseandthe
cylinderonconeisnotanoptimalgeometry.
The predicted overall drying performance of different geometry designs
show that pure conical geometry may present a better average volumetric
evaporationintensity.
Limitation:noexperimentaldatatocompare
Thepredictedresultsareusefulforthespraydryervendorsor userswhoare
interestedindevelopingnewdesignsofspraydryers.
Overallheatandmasstransfercharacteristicsofthefourchambers
CaseA CaseB CaseC CaseD
Volumeofchamber(m
3
) 0.779 0.501 0.623 0.623
Evaporationrate(10
3
kg/s) 0.959 0.951 0.9227 0.955
NetHeattransferrate(W) 2270 2236.88 2165.1 2285
Heatlossfromwall(W) 2487.56 2067.67 2300.96 2038.76
Average volumetric
evaporation intensity q
m
(10
3
kgH
2
O/s.m
3
)
1.23 1.91 1.48 1.53
Average volumetric heat
transferintensityq
h
(W/m
3
)
5463.27 8591.9 7168.6 6940.2
Horizontalspraydryers
Horizontalspraydryers
Horizontalspraydrying Streamlinepatterns
Recirculationzoneresultinginparticleremoistenor
overheated
BetterperformancecanbeobservedinCaseGandH
More
particles
exitfrom
outlet
Horizontalspraydrying Particletrajectories
Coffeespraydrying
Depositconditions:
Topconewall:1(Matched)
Cylinderwall:1293(Not
Matched)
*
Fouroutlets:340(Matched)
ConicalWall:329(Matched)
Otherwalls:37(Matched)
*Dueto18hammersshocking
Temperaturecontoursinthedryingchamber
Spraydryers,bothconventionalandinnovative,
willcontinuetofindincreasingapplicationsin
variousindustries.
Someofthecommonfeaturesofinnovationsare
identified.ThereisneedforfurtherR&Dand
evaluationofnewconcepts.
Spraydryingisanimportantoperationfor
industriesthatdeservesmultidisciplinaryR&D
preferablywithcloseindustryacademia
interaction
ClosingRemarks
ClosingRemarks(Continued)
Inthefuture,themathematicalmodelofspray
dryingwillincludenotonlythetransport
phenomenabutalsoproductqualitypredictions.
Inthemeantime,itisnecessarytotestand
validatenewconceptsofdryinginthelaboratory
andifsuccessfulthenonapilotscale.
Numerouspapersdealingwithmathematical
modelsforconventionalandmodifiedspray
dryersappearregularlyinDryingTechnology
AnInternationalJournal
Please e-mail for further information:
mpeasm@nus.edu.sg
Websites: http://serve.me.nus.edu.sg/arun/
Thank you very much!
Thank you for your attention

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