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FEBRUARY 2007 • www.PowderBulkSolids.

com
IN THIS ISSUE

T h e S o u r c e f o r D r y P r o c e s s i n g a n d B u l k H a n d l i n g Te c h n o l o g y

Spray-Dryer
Optimization
Read more on page 12

Official Publication of the


TechnicalExclusive

Spray-Dryer Optimization
By Jim Kent and John McLeod

T
The question is often asked, “How can more capac- monthly basis. In a 30-day month, there are 720
ity be gotten from our spray dryer?” Or, “What is hours during which a dryer can run. How many
the greatest amount of powder that this dryer can hours per month is it in fact running? How many
produce?” Optimization of a spray dryer most often hours per month are lost to clean in place (CIP)?
means greater capacity, greater energy efficiency, How many hours are lost to process-related prob-
and lower manpower input. lems such a plugging, build-up, etc.? In many
Optimization is a complex and multifaceted goal cases, more production can be achieved by reduc-
that is best looked at in three ways. First, one can ing downtime than by trying to operate each pro-
address the question from the standpoint of maxi- duction hour close to the theoretical maximum.
mizing any single hour of production—that is, by The third, and often overlooked, approach is to
maximizing inlet temperature, outlet temperature, maximize dryer production on an annual basis
feed temperature, feed solids, etc. This procedure based on changes in ambient conditions. Spray dry-
can be both theoretical and scientific. ers almost always run better in winter than in sum-
The second way to address the problem is on a mer. This has to do with the amount of moisture in

A large dairy multistage dryer with insulation panels that can provide substantial energy savings
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the ambient air. not occur.


When the mois- Another reason for limiting the
ture in the ambi- inlet temperature is related to safety. If
ent air is higher, product builds up in the dryer, particular-
less water can be ly in areas next to high-temperature sur-
evaporated in the faces, product may ignite. Sugar-based
spray-drying products can
process. autoignite when
Because each opti- wall build-up
mization procedure has reaches certain
unique requirements, it is difficult to give thicknesses at cer-
one-size-fits-all answers. But tain moisture levels and
if an operation is analyzed temperatures. Being aware
critically, if the right ques- of these conditions enables
tions are asked and if clear users to set reasonable limits for the
methods are applied to find inlet temperature.
solutions, operations can be Plant operators should know why inlet
improved. and outlet temperatures are set at particu-
The Niro CIP lar levels. Just because limits exist and
nozzle valve features
Improving Capacity a retractable design.
the spray dryer has run for years does not
Simply stated, the capacity of mean that operating conditions should
spray drying is measured by the not be evaluated and optimized. Limits
amount of water evaporated. Evaporation Using instrumentation to determine when are often in force for reasons that no
is defined as the difference between inlet the ambient conditions change allows longer exist.
and outlet temperature, or T, in the dry- operators to adjust the drying parameters Feed temperature, particularly in existing
ing air. The larger the T, the greater the to account for changing conditions while plants, can also be optimized.
capacity of the spray dryer. The goal in maintaining optimized production. Theoretically, heating feed as close to the
optimizing a spray dryer’s capacity is to Another key to achieving optimal drying dryer’s inlet temperature as possible is
increase T by raising the inlet tempera- conditions is spray-dryer inlet tempera- ideal. All of the energy available from the
ture or lowering the outlet temperature. ture. The higher the inlet temperature, air heater can then be used for water
What is the optimal outlet temperature? the more energy is available for evaporat- evaporation, with no energy going toward
The outlet temperature is a manifestation ing water. Obviously, spray dryers do not heating the residual product. In most
of the relative humidity in the outlet air. operate with infinitely high inlet tempera- cases, it is not possible to heat the product
If the outlet temperature is too low, the tures. There are good reasons for limiting greatly without causing product degrada-
product particles in the drying chamber inlet temperature, and they are generally tion. Elevating the temperature as high as
will not become dry enough in the time process, product, or safety related. Inlet the product allows without degradation
allowed, enabling sticky particles to cause temperature can be limited for process yields extra capacity from the spray dryer
blocking or plugging. If the outlet temper- reasons when the T has been optimized by acquiring heat from a source other
ature is too high, excess capacity remains and the maximum outlet humidity has than the main air heater.
unutilized. The proper outlet tempera- been reached. This means evaporating as Finally, using the highest concentrations
ture—or more specifically, proper outlet much water as possible and operating just of feed solids yields greater capacity. This
relative humidity—is product- and dryer- above the product’s sticky point. topic, however, is beyond the scope of the
specific, but once established, it remains Build-up can occur in vessels that operate spray dryer itself.
constant for a specific product in a partic- above a certain inlet temperature or
ular dryer. below a certain outlet temperature. In Decreasing Downtime, Increasing
To develop a viable dry particle, a dryer addition, vessels can experience bridging. Run Time
should operate just on the safe side of This is a manifestation of operating with a A plant may decide at some point that it
“dry enough” while avoiding “too dry,” T greater than that which can produce a requires all of the 720 hours in a 30-day
which results in underutilization. viable dry particle. month to meet its production require-
Understanding these principles and using Inlet temperature can also be limited for ments. During a production month, there
a modern control system with the instru- product reasons. If the product becomes are two ways to understand the amount of
mentation needed to collect operating denatured, burned, deprived of desired time that is not spent in spray drying.
data are the primary means to achieve volatiles, or degraded in other ways at The first is the planned time spent per-
optimal drying conditions. high inlet temperatures, the drying inlet forming processes such as cleaning or
An instrument for measuring incoming temperature is limited to a point below CIP. The second is dryer-related
air moisture is key to good operation. which the undesired characteristics do unplanned downtime, such as unplugging
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There has been a ing speed of feed system 1 is reduced


trend toward using while the processing speed of feed system
spray dryers with two 2 is ramped up. Production capacity
feed systems, each of always remains constant during this oper-
which can operate at ation. Feed-system CIP setup is taken out
100% capacity. While of the critical path and can be performed
this procedure works when convenient.
particularly well for If CIP is not planned immediately after
nozzle atomization the feed-system switch, accommodations
systems, it can pro- can be made for the high-pressure feed
vide benefits for system to purge the nozzle lances with
rotary atomization compressed air, or a recirculating loop can
systems as well. If be created to flush the system with water.
feed-system CIP An added benefit of using a dual-feed sys-
requires that a spray tem and switching back and forth is the
dryer be down for sev- reduction of drying-chamber fouling,
eral hours per day or which is most often caused by startups
week, those hours can and shutdowns. If startups and shutdowns
be regained by using a can be minimized or eliminated, the time
dual-feed system. between chamber washes can be extend-
A dual-feed system ed. With fewer startups and shutdowns,
can be used in two the use of fans and heaters between
ways. First, and most spray-drying operations can be reduced,
simply, an exact dupli- resulting in energy savings.
cate of the feed sys-
tem, whether rotary Spray-Dryer Cleaning
or nozzle, can be built Aside from operations, the most impor-
up to the point of con- tant events in the life of a spray dryer are
nection with the planned or unplanned cleans. For some
atomizer. When feed operations, cleaning may be performed
A service technician with a spray dryer system 1 is shut down daily to separate batches or allergen class-
at the end of a batch, es. For other operations, cleaning may
cyclones. Even if a plant does not need all the nozzle lances or rotary atomizer are take place annually.
720 hours, operating in the most efficient removed for cleaning. Clean nozzle lances First, personnel must ask why the spray
way possible leads to labor savings. or a clean rotary atomizer are immediate- dryer is going to be cleaned. Generally,
If the dryer feed system is down for ly installed and connected to feed system there are five answers to this question:
cleaning, dryer downtime results, reduc- 2, after which the spray dryer is put back
ing the amount of available time in a pro- into operation. Then feed system 1 can be 1. To remove buildup that can result in
duction month. In a food or dairy plant, cleaned when convenient. In this proce- fire or explosion.
the feed system for the spray dryer often dure, CIP does not interfere with produc- 2. To eliminate buildup that is causing
must be washed or CIPed daily. In food tion. product quality issues.
plants that often switch between products, Generally, switching between two feed 3. To separate product groups or classes
batches and products must be separated. systems can take between 30 and 60 min- to prevent cross-contamination.
A hot issue is dealing with allergens and utes. But the 1 to 3 hours required for CIP 4. To eliminate bacterial growth that can
cleaning between allergen classes. do not cut into production and are gained cause product quality issues.
Many simple incremental operational back as time available for spray drying. 5. As part of regularly scheduled main-
improvements can be made in the feed- The second way to implement a dual-feed tenance.
system CIP to shorten turnaround times. system is more complex and only applies
For example, is the labor required to to nozzle atomization. This method Often, cleaning is performed to address
remove nozzle lances from the spray requires an air disperser with double the and eliminate the root causes of produc-
dryer and hook them up for cleaning pro- number of nozzle lance locations. If a tion issues. If buildup can be minimized—
ceeding as efficiently as possible? A sec- dryer has 6 nozzles, the air disperser for example, by performing fewer startups
ond set of nozzle lances that has been must be rebuilt to hold 12 nozzles, 6 of and shutdowns—wash frequency required
pressure tested and is ready for installa- which are used at any given time. Then for preventing fire hazards or product
tion will save operators from having to the spray dryer will never have to be shut quality issues can be reduced. Ultimately,
cover the same ground twice. down. At the end of a batch, the process- maximizing the time between cleans or
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CIPs will also maximize the time allowed the most common causes of unplanned 120°–130°F. If the room in which the ves-
for production. spray-dryer downtime is the plugging of sel is situated is 80°F, there is enough
While performing cleans, three areas can cyclones, chamber outlets, conveying temperature differential to cause heat loss
be evaluated to achieve the most efficient lines, and similar equipment. Plugging and condensation, leading to product
time utilization: setting up the dryer for has two main causes: mechanical issues plugging or bridging. If the vessel is insu-
cleaning or CIP, the cleaning or CIP pro- and moisture. Mechanical issues— lated and clad or heat jacketed, these
cedure, and drying out the equipment whether bridging or reduced flow—are problems are generally eliminated.
and preparing it for production again. much easier to deal with than moisture. Nevertheless, other conditions exacerbate
Setting up a CIP and preparing equipment These problems are handled using the problems.
for production are generally manpower mechanical means such as pneumatic A crucial component is the cyclone tip or
issues. Establishing piping connections or hammers, bridge breakers, or increased product outlet. In the cyclone tip, the
isolating pieces of equipment can be outlet sizes. rotational velocity of the air is high.
accomplished using more manpower or The more difficult issues include mois- Inversely, because the air velocity is high,
automation. For example, if spray balls ture and condensation. By definition, the the air pressure is low. For example, in a
are still being installed manually, perma- air inside a spray-drying process vessel— high-efficiency cyclone with 6 in. of water
nently mounted retractable spray balls be it a chamber, cyclone, or baghouse—is column differential pressure between the
can be added to reduce labor and time moist and warm, while the temperature air inlet and outlet, the static pressure in
requirements. outside the vessel is cooler. If the internal the tip can be –20 in. water column. Such
During the cleaning or CIP cycle itself, surface of the vessel is allowed to cool low pressure would be the same as mov-
timelines can be improved by addressing below the dew point of the moist air, con- ing the plant from sea level to 1400 ft
the four parameters that affect cleaning: densation will occur. For a process with a above sea level. Such low absolute pres-
solution delivery pressure, solution chem- 160°–180°F dryer outlet temperature, sure in the area of the cyclone tip causes
ical strength, solution temperature, and dew points can be in the range of fog or condensation in the air.
duration. Improving
any of the first three
parameters generally
reduces the time
required to complete a
cleaning cycle. With
one or two operators,
performing a simple
hot-water clean of a
small-sized modern
spray dryer system to
separate product types
or batches can often be
accomplished in
approximately three
hours—from going off-
line to resuming pro-
duction. Chemical
cleans of a larger dryer
with a month’s worth
of production build-up
can be turned around
in 8–16 hours. In many
operations, however,
24–48-hour cleans are
highly valued.
Unplanned Downtime
In dealing with
unplanned downtime,
there are myriad
mechanical- and
process-related reasons
for shutdowns. One of The integrated filter dryer features an integrated fluid bed and filter arrangement.
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Why is the cyclone tip the most problem- trial high-pressure pump is used to test capacity, the dryer should be operated as
prone component of a dryer? If three each nozzle with water after it has been close as possible to the maximum total
effects are combined—smeared product assembled. This test can be done on a moisture of the chamber outlet air, a
caused by rotation, air leakage into the second set of nozzle lances while the parameter measured in pounds of water
cyclone from a rotary valve or similar dryer is operating so that the tested per pound of dry air (lb lb).
device, and the low absolute pressure lances can be installed during the next Once the dryer inlet temperature, dryer
inside the vessel—plugging can occur. changeover. outlet temperature, and other parameters
A second area to explore is the nozzle have been optimized for a specific prod-
lances in a nozzle spray dryer. Operators Effect of Ambient Conditions uct under specific conditions, dryer outlet
regularly install and remove nozzles, dis- Humidity levels in the dryer inlet air moisture will be optimized. Then the
assembling and reassembling them. resulting from the seasonal variability in plant should be operated as close to this
Handling the small parts that comprise a ambient air conditions play an important theoretical maximum as possible. This
spray nozzle and assembling them cor- role in standardizing incoming air in procedure is difficult to carry out because
rectly so that they can operate at many open-cycle dryers and dryers without of weather and seasonal changes.
thousands of pounds per square inch of inlet-air cooling systems. To understand Facilities often hope to solve this difficul-
pressure is difficult. Incorrectly installed this, it is necessary to understand a pri- ty by installing an instrument to measure
spray nozzles result in poor product quali- mary maxim of spray drying: Dryer the total moisture of the chamber outlet
ty and require operators to shut down and capacity is limited by the total moisture in air and then program a control loop to
restart the spray dryer, leading to produc- the air leaving the spray-drying chamber. allow the dryer to operate at a setpoint
tion losses. In simpler terms, if the air leaving the just below the maximum. This is not pos-
One way to solve this problem is to pres- chamber is too moist, a viable stable parti- sible, however, since any commercially
sure test the nozzles before they are cle is not produced and the product tends available instrument, such as a hot-wire
installed. A small operation can be set up to be sticky. If the air leaving the cham- anemometer or a humidity transmitter,
either near the dryer top or in another ber is too dry, some drying capacity would be quickly fouled by the powder in
part of the plant in which a small indus- remains unused. To maximize dryer the air stream. The problem must be
approached from a differ-
ent angle.
First, it is important to
understand the three
sources of water in the out-
let: the humidity in the
ambient air absorbed into
the dryer, combustion prod-
ucts if a direct-fired gas
burner is used as a source
of heat, and the water
evaporated in the spray-
drying process. If the mois-
ture contributions from the
first two sources are
reduced, the contribution
from the third can be
increased. If the moisture
from the first two sources
can be measured and con-
trolled, one can operate
with much less of a margin
on the third and thereby
maximize capacity.
How does one measure
and control this? Using
the units of measure used
for outlet humidity (lb
lb), every contributing
component is measured.
The integrated filter dryer features an integrated fluid bed and filter arrangement. This means measuring
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the two or three components that con- metric calculation can be made to calcu- Conclusion
tribute to the water total and all of the late the exact moisture contribution. Corporate profitability drives the need to
air components. Finally, the volume of water contribution understand the science of spray dryers
First, it is necessary to measure the ambi- from the evaporated water must be meas- and their optimization. Consequently, the
ent air moisture with some sort of ured. Since either a nozzle spray system cost of implementing any of the sugges-
hygrometer that sends data back to the or a rotary atomizer system is fed with a tions discussed in this article must be
control system. If some air is taken from positive-displacement pump, the volume weighed against the opportunity cost of
inside the plant and some from outside, of water pumped into the dryer can be an extra pound of production or an extra
two instruments can be needed. Air vol- calculated from the pump speed, pump available hour of uptime. No move in the
ume must be measured for each air displacement, and solids content. This direction of optimization can be justified
stream. This can generally be done using procedure is generally more accurate than unless it results in a positive financial out-
a pitot tube with a differential-pressure using a flowmeter, but mechanical ineffi- come.
transmitter, which calculates the air vol- ciency and slippage must be accounted Jim Kent is the sales manager for the food
ume in the control system. Alternatively, for to ensure accuracy. and dairy division of Niro Inc. in Hudson,
something similar can be done using a When all the moisture and air inputs have WI. Kent has a BS in aerospace engineering
hot-wire anemometer. been collected, the final calculation can from the University of Minnesota. He can be
If a spray dryer has a direct-fired gas be made in the control system. reached at 715-377-0536 or jpk@niroinc.com.
burner that runs on natural gas or Operational data must be collected to John McLeod is the rebuild sales engineer of
propane, moisture is added to the drying indicate when the dryer is operating cor- Niro Inc. in Columbia, MD. McLeod has a
air stream as a product of combustion. rectly and when it becomes plugged. BS in chemical engineering from North
This can amount to a 5 to 10% increase in Alarms or automation systems can be put Carolina State University and an MBA from
the moisture contribution, depending on in place to ensure that the spray dryer is the University of South Carolina. He can be
the specific conditions. An accurate gas operating at its optimum level without reached at 410-997-6670 or
meter can send the gas consumption data being in danger of plugging or experienc- jpm@niroinc.com.
to the control system, where a stoichio- ing a wetdown condition.

Reprinted from Powder Bulk Solids, February 2007 • Copyright © 2007 Canon Communications LLC
Niro Inc. • 9165 Rumsey Road • Columbia, MD 21045 • USA • Tel 410 997 8700 • Fax 410 997 5021

Niro Inc. • 1600 O’Keefe Road • Hudson, WI 54016 • USA • Tel 715 396 9371 • Fax 715 386 9376

E-mail info@niroinc.com • Website www.niroinc.com

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