Design of a Spray dryer in a Milk industry

Submitted in partial fulfillment of the requirements for the course

Process Equipment Design and Economics (CHE2002)

in
Chemical Engineering

by

Anjali Kabra 16BCM0002

Mohamed Khalil Kallangodan 16BCM0055
Shrinkhla 16BCM0062
Rishabh Bothra 16BCM0074

Under the guidance of

Dr. Mahesh Ganesapillai (Associate Professor)

SCHEME
VIT, Vellore.

April, 2019
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DECLARATION

We hereby declare that the project entitled “Design of Spray dryer in milk industries”
submitted by us, for the award of the credits of the course process equipment and design in
chemical engineering to VIT is a record of bonafide work carried out by us under the supervision
of Dr. Mahesh Ganesapillai.

We further declare that the work reported in this Report has not been submitted and will not be
submitted, either in part or in full, for the award of any other degree or diploma in this institute or
any other institute or university.

Place : Vellore
Date :
Signature of the Candidate
 II

CERTIFICATE

This is to certify that the project entitled “Design of Spray dryer in milk industries” submitted by
Anjali Kabra 16BCM0002, Mohamed Khalil Kallangodan 16BCM0055, Shrinkhla 16BCM0062,
Rishabh Bothra 16BCM0074, SCHEME, VIT, for the award of the J component credits of the
subject PEDE in Chemical Engineering, is a record of bonafide work carried out by them under
my supervision during the period, 01. 12. 2018 to 02.04.2019, as per the VIT code of academic
and research ethics.

The contents of this report have not been submitted and will not be submitted either in part or in
full, for the award of any other degree or diploma in this institute or any other institute or
university. The thesis fulfills the requirements and regulations of the University and in my opinion
meets the necessary standards for submission.

Place : Vellore
Date : Signature of the Guide
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ACKNOWLEDGEMENT

We would like to thank our Professor Dr. Mahesh Ganesapillai who constantly supported us and
guided us for completion of this study.

We would also like to thank the Dean (SCHEME) Dr Shishir Kumar Behera for helping us
whenever we found ourselves in a difficulty and granting us the permission to go forward with the
project.

We would also like to thank VIT for providing us with all the resources and permission to use lab.

Special thanks to our families for care and support.

Anjali Kabra
Mohamed Khalil Kallangodan
Shrinkhla
Rishabh Bothra
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Table of contents

Sl No. Topic Page number

Declaration I

Certificate II

Acknowledgements III

List of figures V

Abstract VI

1 Introduction 1

2 Design Calculations 7

3 3D Modeling Of The Spray 15

Dryer

4 Summary 18

5 Conclusion 19

6 References 20
 V

List of figures

Sl No. Figure name Page number

1 Spray Dryer Side View 15

2 Spray Dryer Front View 16

3 Spray Dryer Feed Inlet Pipe 17

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ABSTRACT

Spray Dryer is extensively used in milk industries for producing milk powder and is one of the key
operations. During the process, a liquid feed is converted to a dried form of particulate by
atomizing the feed into the hot gas within a drying chamber. If the process is inefficient due to
various factors like caking, stickiness, economic losses etc then there is a need for improvement
of product quality and minimizing the possible problems during the spray drying processes are the
major concerns of dairy powder manufacturers. The main parts of a typical spray dryer are
atomizer (rotary disc in our case), Cyclone Separator, heater, compressor, and the drying Chamber.
We have done the design calculations of the spray dryer and 3D modeling of the drying chamber
in the project.
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1. INTRODUCTION
Spray drying is the change of feed from a liquid state into a dried structure by showering the feed
into a hot drying medium. It is a one stage nonstop handling activity. The feed can be either an
slurry, suspension or a glue. The dried item shapes powder comprising of single particles or
agglomerates, all relying on the physical and compound properties of the feed and the dryer
structure and task. In the course of the most recent three decades shower drying has experienced
escalated innovative work, so present day hardware can meet the prerequisites to create a powder
with required particulars.
1.1 History
One of the initial spray drying licenses was connected for in 1901 by the German Mr. Stauf who
spray the milk by methods for spouts into a chamber with warm air. The principal genuine leap
forward, be that as it may, was in USA in 1913, when the American Mr. Dim and the Dane Mr.
Jensen built up a spray dryer and began to deliver and sell drying establishments on a business
scale. The primary revolving atomizer was created by the German Mr. Kraus in 1912, yet not until
1933, when the Danish architect Mr. Nyrop documented his reality patent, along these lines of
atomization had a leap forward. After these pioneers had framed the reason for the cutting edge
dry milk industry the improvement went quick, and the hardware introduced these days is as a rule
extremely complex and includes an exceptionally specialized and mechanical structure.
1.2 Operation
The feed is siphoned from the item feed tank to the atomizing gadget which is situated noticeable
all around disperser in the highest point of the drying load. The drying air is drawn from the
environment by means of a channel by a supply fan and is gone through the air radiator to the air
disperser. The atomized beads meet the sight-seeing and the vanishing happens cooling the air in
the meantime. After the drying of the shower in the chamber, most of the dried item tumbles to the
base of the chamber and enters a pneumatic passing on and cooling framework. The fines, which
are the particles with a little distance across, will remain entrained noticeable all around, and it is
consequently important to go the air through twisters for partition of fines. The fines leave the
violent wind at the base through a locking gadget and enters the pneumatic framework, as well.
The air goes from the violent wind to the environment through the fumes fan. The two parts of
powder are gathered in the pneumatic framework for passing on and cooling and are gone through
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a violent wind for partition, after which they are packed away off. The instrumentation contains
sign of the temperature of the delta and outlet air, just as programmed control of the channel
temperature by changing the steam weight, measure of oil or gas to the air warmer, and
programmed control of the outlet temperature by adjusting the measure of feed siphoned to the
atomizing device.
A conventional spray dryer consists of the following main components: Drying chamber (1) Hot
air system and air distribution (2) Feed system (3) Atomizing device (4) Powder separation system
(5) Pneumatic conveying and cooling system (6) Fluid bed after-drying/cooling (7)
Instrumentation and automation (8)

1.3 Drying Chamber

Different structures of drying chambers are seen available. The most widely recognized one is the
round and hollow load with a cone of 40-60 degrees, so the powder by gravity can leave the load.
The chamber is likewise observed with a level base in which case a scrubber or suction gadget is
required for expelling the powder division from the chamber. Additionally, flat box type drying
chambers are seen, and they, as well, work with a constrained (for example scrubber or screw)
powder expulsion framework. See the diverse kinds of drying chambers in Fig. 39. For the most
part, it very well may be presumed that chambers with a cone for gravity release of the powder
give the best adaptability for adjusting different drying forms like incorporated liquid beds or belts
to the plant and subsequently offer the best potential outcomes for drying diverse items

In the tall-structure drying chamber, the accentuation has been on planning a plant with a laminar
wind stream and an uncommon air outlet framework, where the width of the cone is greater than
the distance across of the barrel shaped part hence framing a ring conduit named a "clamor". This
limits the twister portion by the low speed of the fumes air. This chamber is uniquely appropriate
for infant nourishment items or protein items dried from a low solids content in the feed.
1.4 Hot Air System and Air Distribution
1.4.1 Air Filtration
Until a couple of years back no exceptional necessities were offered with regards to the filtration
of the procedure air for the shower drying process. Today, in any case, exceptionally severe
prerequisites are displayed by nearby experts so as to guarantee a cleaner activity. Channel
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benchmarks are alluded to in Fig. 40a, and it is vital to allude to the test technique while
determining the channel proficiency in %. Normal for the diverse prerequisites is that:

• The air ought to be prefiltered and provided by a different fan to the fan/channel/radiator room.
This room must be experiencing tension to maintain a strategic distance from unfiltered air to
enter.

• Current practice is as per the following: - Dairy-like items, equivalent to or superior to 3A: Test
technique: - Prefiltration EU4 (or G4) % Dust-spot productivity - Main air filtration EU7 (or
F7) 90% Dust-spot proficiency - Secondary air filtration EU7 (or F7) 90% Dust-spot effectiveness

1.5 Air Heating System

The drying air can be warmed in various ways:

• Indirect: Steam/Oil/Gas/Hot oil

• Direct: Gas/Electricity Indirect Heating A steam warmer is a straightforward radiator.

The temperature to be acquired relies upon the steam weight accessible. Under typical conditions
it is conceivable to acquire air temperatures 10 C lower than the comparing immersion enthalpy
of the steam.

Present day steam radiators are isolated in segments, so the virus air initially meets the condensate
segment, at that point an area with low steam weight (which is normally the greatest one so as to
use however much low-weight steam as could reasonably be expected), and afterward the air at
long last enters the high-weight steam segment. The air warmer comprises of lines of finned tubes
housed in a protected metal case. The warmth load is determined from the amount and explicit
warmth of the air. The warmer size relies on the warmth exchange properties of the cylinders and
blades.
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Steam-warmed air radiators will normally have a capability of 98-99%. As the steam pot is
commonly put at some partition from the air hotter, 2-3 bar g extra weight on the radiator should
be predicted in view of weight incident in the steam pipe and over the controlling valve. To avoid
disintegration of the barrels perceptible all around hotter it is endorsed to use solidified steel.

1.6 Air Distribution

The air conveyance is a standout amongst the most indispensable focuses in a shower dryer. There
are different frameworks relying upon the plant structure and the sort of item to be delivered. Dryer
configuration falls into three classes: co-current, counter-current and blended stream.

Be that as it may, as the objective in the dairy business is to get the best blend of the hot
approaching air and the gather beads so as to get a quick dissipation, just cocurrent dryer
configuration is utilized. On the off chance that the dryer is with a flat load, the air disperser is
masterminded like a plenum load, and every spout will be encompassed by an air stream. A similar
framework is additionally found in vertical barrel shaped dryers. In any case, the most widely
recognized is that the air disperser is arranged over the dryer roof, and the atomizing gadget is set
amidst the air disperser along these lines guaranteeing an ideal blending of the air and the atomized
beads. In round and hollow vertical dryers it is likewise observed that the entire roof is punctured
consequently making an attachment stream air stream - various spouts are arranged in the
punctured plate so as to guarantee that the air is cooled by the concentrate. This framework, be
that as it may, makes fines return muddled, and the reachable air speed/spout position isn't ideal
for a productive drying. It ought to be noticed that an air disperser ought to be able to control the
air and the atomized beads the correct way so as to keep away from stores in the drying chamber.

1.7 Feed Tanks

It is prescribed to utilize two feed tanks and change from one to the next at any rate once at regular
intervals. This is because of the danger of microscopic organisms development in the feed
regularly having a temperature of 45-50 C. One is in this way being used while the other one is
being washed. The measure of each tank ought to relate to 15-30 min. of the limit of the dryer. The
feed tanks are outfitted with level pointers and shower spouts for programmed CIP cleaning. In
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some cases, the feed tanks are supplanted by vacuum tanks as a coordinated piece of the last
component of the evaporator.
1.8 Water Tank
The water tank is utilized amid begin and stop of the plant, and if amid the keep running there will
be an unexpected deficiency of concentrate. Then again, level transmitters can be put in the feed
tanks, and a water supply pipe associated with the feed tank, in which case the water tank is
dodged.

1.9 Concentrate Pump

On the off chance that a revolving atomizer is utilized, the most well-known feed siphon is either
the mono sort or a diffusive siphon. The mono siphon requires less vitality and can deal with
concentrates of a higher consistency than the radiating siphon, yet is increasingly costly.

1.10 Preheating System

Nozzle atomization requires higher feed temperature (lower consistency) than that originating
from the evaporator. Preheating is, in any case, profitable from an atomization perspective,
additionally for revolving atomization. Along these lines, a concentrate preheater is prescribed.
Two sorts can be utilized, either roundabout or direct.
1.11 Filter
An in-line channel is constantly fused in the feed framework to keep away from knots and so forth
going to the atomizing gadget.

1.12 Homogenizer/High-Pressure Pump

In the event that entire milk powder or other fat-containing items ought to be created, it is
prescribed to fuse a homogenizer so as to diminish the free fat substance in the last powder. A two-
arrange homogenizer is favored. First stage is worked at 70-100 bar g, and the second stage at 25-
50 bar g. Generally the homogenizer and feed siphon are consolidated in one unit. In the event that
spout atomization is utilized, at that point a higher weight (up to 250 bar g for the spouts + 150 bar
g for homogenizing) is required, and a joined homogenizer/high-weight siphon is picked to spare
expense. A variable speed drive for controlling the feed stream and in this way the outlet
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temperature is favored, as an arrival valve will in general give wild holding time bringing about
thickness issues.

1.13 Atomizing Device

The point of atomizing the concentrate is to give an extensive surface, from which the dissipation
can occur. The littler beads, the greater surface, the simpler vanishing, and a superior warm
effectiveness of the dryer is acquired. The perfect from a drying perspective would be a splash of
drops of same size, which would imply that the drying time for all particles would be the equivalent
for acquiring an equivalent dampness content. By and by, be that as it may, no atomizing gadget
has yet been intended to create a totally homogenous splash, albeit present structures have a high
level of homogeneity. From a powder mass thickness perspective a homogenous shower isn't
needed, as this would mean a powder with low mass thickness, and that would mean an expansion
in pressing material.
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2. DESIGN CALCULATIONS

Basis: Milk to be dried from 87 wt % to 3.5 wt %

Assumed Data:-

Feed rate of milk (Ls) = 1000 kg/hr

Inlet heated air of (TDB) = 170 0C
Outlet air Temperature = 93 0C
Inlet temperature of liquid = 80 0C
Outlet temperature of milk = 73 0C
Specific heat of milk = 0.94 cal/gm/0C
Diameter of the Disk Atomizer 5 –35 cm .
Rotational speed = 5,000 - 25,000 rpm
Peripheral speed = 6,000–12,000 m/min
Mean particle size = 40 – 125 microns
Atomiser selected is Rotary disk atomiser
Mean particle size assumed = 100 microns

On calculating:

Feed rate (F) = (1+X1) Ls =1870 Kg/hr= lb/min

Data Taken:
Diameter of disk = 0.59 ft
Vane height = 0.406 ft
Vane length = 1 ft
No of vanes = 60

Rotational speed N= 546.81*60/(1.8526) =17709.49 rpm

We take N=17750 rpm
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2.1 Power consumption

P = 1.02*10-8 * F * ( N * d )2
= 1.02* 10-8 * 36.7437 * (17750 * 0.59)2
= 20.83 hp

Where:
F = Feed rate of solution in lb/min
N = Rotational speed in rpm
d = Radius of disk atomizer in ft
P = power in hp

2.2 Spray chamber

Gs = Heated Gas Flow Rate in kg/hr
Ls = Milk Flow Rate in kg/hr
X1 = Moisture content in the entering milk (kg moisture / kg milk)
X2 = Moisture content in the exit milk (kg moisture / kg milk)
Y1 = Humidity of entering air (kg moisture / kg air)
Y2 = Humidity of outlet air (kg moisture / kg air )
T1 = Temperature of inlet air
T2 = Temperature of outlet air
t1 = Temperature of inlet milk
t2 = Temperature of exit milk

2.2.1 Equations for Spray Chamber

2.2.1.1 Mass balance
Ls * (X1-X2) = Gs * (Y2-Y1) -----------(1)

2.2.1.2 Enthalpy Balance

Ls * (HL1 - HL2) = Gs * (H2 – H1) -----------(2)
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where,
HL1 = Enthalpy of entering solid in kJ/kg of dry solid
HL2 = Enthalpy of exit solid in kJ/kg of dry solid
H1 = Enthalpy of entering air in kJ/kg of dry air
H2 = Enthalpy of exit air in kJ/kg of dry air

2.2.1.3 Enthalpy Equations:

HL1 = (Cps+X1*Cpw)*t1
HL2 = (Cps+X2*Cpw)*t2
H1 = (Cpa+Y1*Cpv)*T1 + Y1*λ
H2 = (Cpa+Y2*Cpv)*T2 + Y2*λ

Cps = Specific heat of milk = 3.93 kJ/kg/0C

Cpw = Specific heat of water = 4.2 kJ/kg/0C
Cpv= Specific heat of water vapor = 1.89 kJ/kg/0C
Cpa = Specific heat of air at avg. temperature = 1.0312 kJ/kg/0C
λ = Latent heat of vaporization= 2510.7 kJ/kg

X1 = 0.87 X2 = 0.035
Y1 = 0.01517 (By psychometric chart at given DB & WB) humidity of inlet air
HL1 = 318.054 kJ/kg of dry milk
HL2= 297.621 kJ/kg of dry milk
H1= 218.265 kJ/kg of dry air

Simultaneously solving Mass balance and Enthalpy balance equations (1) and (2) we get:
Y2= 0.082

Evaporation rate of water = (0.87-0.035)*1000= 835 Kg/hr

Moisture removed per kg of dry air = (0.082-0.01517) = 0.06683 kg water per kg of dry air
Therefore, Gs = 835/0.06683  12495 kg/hr
Gs = 12,495 kg/hr
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2.3 Humid Volume

Ma = Molecular wt of air =29 g/mol

Mw = Molecular wt of water 18 g/mol
Tg = Temperature of gas in 0C
P = Pressure in N/m2
Y = Humidity of air in kg of moisture/ kg of dry air

Inlet (Vin) = 1.302 m3/kg dry air

Outlet ( Vout) = 1.19 m3/kg dry air
Vavg = (Vin + Vout)/2= 1.246 m3/kg dry air
Droplet Diameter assumed to be 100 microns = 100 * 10-6 m

2.4 Operating Velocity Calculations

2.4.1 Settling Velocity
For stoke’s law region

Dp = Drop Diameter in m
ρp = Density of droplet in kg/m3
ρf = Density of air at avg temperature in kg/m3
µ = Viscosity of air at avg temperature
Vs= Settling velocity
g = Acceleration due to gravity
Density of milk = 1034 kg/m3
Density of water = 1000 kg/m3
Density of solid particles = (87*1000 + 13*1034)/100
ρp = 1004.42 kg/m3
Average temp = (170+93) / 2 = 131.5 0C
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Density of air at avg temperature ρf = 0.865 kg/m3

Viscosity of air at avg temperature µ = 23.329*10-6N/m
Settling velocity Vs = 0.234 m/s

2.4.2 Reynolds number

Re = (Dp* Vs * ρp ) /µ = 1.005<2
Thereby, Stoke’s Law is applicable and now

2.4.3 Operating Velocity

( Va) = 2 * Settling velocity = 2 * Vs = 0.6155 m/s

2.5 Column Diameter of Spray Chamber

Column Area Ac= (Gs* Vavg)/ Va
Gs = 12495 kg/hr
Vavg = 1.246 m3/kg dry air
Va = 0.6155 m/s
Ac = 9.24 m2

Column Diameter (Dc)

Dc = 3.43 m
For safety purposes, assuming 15 % safety

Dc = 1.15* Dc
Dc = 3.95 m

2.6 Residence time

td = 50√X1
td = residence time in sec
X1 = mass ratio of water to milk in feed = 0.87
td = 46.64 sec
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2.7 Time required to evaporate moisture from droplet

𝛉p = time required to evaporate moisture from droplet

ρp= Density of feed
λw= Latent heat of vaporization at normal boiling pt. = 2256.9 kJ/kg
Kf = Thermal conductivity of air at avg temperature = 0.033925 Watt/m/K
ΔTt= Temperature driving force = Drying gas film temp –Temp of dry solid surface
ΔTt = Tavg – (t1+ t2) / 2 = 55 0C
θp = 0.97 sec

As θp is less than td, hence evaporation of the drops can take place and design is acceptable

2.8 Chamber Dimensions

It is a cylindrical chamber with a conical bottom.
Total Volume of Chamber
Total Volume of chamber (Vt) = Gs*Vavg*td = 201.7 m3
Minimum height of cylindrical (hmin) = Vs*θp = 0.227 m
Recommended height of (hcyl) = 0.6 * Dc = 2.37 m cylindrical portion

2.8.1 Volume of conical portion of Chamber

Volume of the conical portion of the chamber VCone = 172.3 m3

2.8.2 Height of Conical portion of the Chamber

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hcone = Height of the conical portion of the chamber

hcone = 12.18 m

Cone angle α = 20.36316 degree

2.9 Mechanical Design

2.9.1 Thickness of Chamber
tmin = (Dc+100)/1000 = 0.26 inch
Dc is in inches & tmin is in inches
Since head and wall are under same stress, so we can assume the same thickness for both.

2.9.2 Dust collector

2.9.2.1 Outlet area of the dust collector

Ad= 4.25 m2

2.9.2.2 Diameter of dust collector

Dd = 2.33 m

2.9.2.2 Length of dust collector

Ld = Dc /8 = 0.49 m
Ld = 0.49 m

2.10 Hot Air Inlet

Assume operating air velocity vair = 10 m/s
Minimum cross sectional area = (Gs* Vavg)/ vair = 0.43 m2
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Contamination of outlet air with fine particles requires a higher cross sectional area for outlet
duct than that of inlet duct.
A rectangular duct having length to breadth ratio 1.2 : 1 is used.
1.2*(breadth)^2 = area of inlet pipe = 0.43m2
Breadth of inlet duct = 0.6 m
Length of inlet duct = 1.2*0.6 = 0.72 m

2.11 Hot Air Outlet

The outlet duct should have a higher cross-sectional area than inlet duct.
Length of outlet duct = 0.8 m
Breadth of outlet duct = 0.65 m
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3. 3D MODELING OF THE SPRAY DRYER USING SOLIDWORKS

3.1 Side view

Fig 1: Side View

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3.2 Front view

Fig 2: Front View

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3.3 View of inlet feed pipe

Fig 3: View of Feed Inlet Pipe

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4. SUMMARY OF DESIGN DATA

 Power consumed = 20.83 hp
 Total Volume of the chamber = 201.7 m3
 Diameter = 3.95 m
 Height: Cylindrical portion (0.6D) = 2.37 m
 Conical portion = 10.18 m
 Total height = 12.55 m
 Bottom cone angle= 20.36316 degree
 Mechanical Design: Shell plate thickness= 0.26 inch
 Hot air inlet duct= 0.72 m x 0.6m
 Hot air outlet duct= 0.8 m x 0.65 m
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5. CONCLUSIONS
A spray dryer model was studied and a model was calculated with the design equations.
Milk to be dried from 87 wt % to 3.5 wt %. An efficiency of 70% is being considered in the
process. As θp is less than td, hence evaporation of the drops can take place and design is acceptable.
Recommended height of (hcyl) = 2.37 m cylindrical portion. Contamination of outlet air with fine
particles requires a higher cross sectional area for outlet duct than that of inlet duct. Total height
of the spray dryer is found to be 12.55 m. Bottom cone angle was found to be 20.3631 degree.
Shell plate thickness was calculated to be 0.26 inch. Total power consumed by the process of spray
drying is 20.83. Total volume of the chamber is 201.7m3.
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6. REFERENCES
https://www.gea.com/en/binaries/Milk%20Powder%20Technology%20-
%20Evaporation%20and%20Spray%20Drying_tcm11-33784.pdf

https://dairyprocessinghandbook.com/chapter/milk-and-whey-powder

https://www.tandfonline.com/doi/abs/10.1080/07373937.2016.1233114?scroll=top&needAccess
=true&journalCode=ldrt20

[1] Clement, K.H., Hallström, A., Dich, H.C., Le, C.M., Mortensen, J. and Thomsen, H.A., On the
Dynamic Behavior of Spray Dryers. Transactions Inst. of Chemical Engineers, 69, 245 (1991).

[2] Kennedy, J. and Eberhart, R.C., Particle Swarm Optimization, International Conference on
Neural Networks. Perth, Australia (1995).

[3] King, C.J., Kieckbusch, T.G. and Greenwald, C.G., Food-Quality Factors in Spray Drying,
Advances in Drying, 3, 71 (1984).

[4] Some properties of Freeze-Dried Milk, Nickerson, T.A et al., Journal of Dairy Science, Volume
35, Issue 1. 77 -85